Download Yamaha YFM35XY Owner`s manual

READ THIS MANUAL CAREFULLY!
It contains important safety information.
OWNER’S MANUAL
YFM35XY
WARNING
LIT-11626-22-44
This ATV should not be ridden by anyone under 16 years of age.
3D5-F8199-13
DIC183
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EBU17092
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
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INTRODUCTION
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Congratulations on your purchase of the Yamaha YFM35XY. This ATV represents the result of many years
of Yamaha experience in the production of fine sporting, touring, and pacesetting racing machines. With the
purchase of this Yamaha, you can now appreciate the high degree of craftsmanship and reliability that have
made Yamaha a leader in these fields.
This manual will provide you with a good basic understanding of the features and operation of this ATV.
This manual includes important safety information. It provides information about special techniques and skills necessary to ride the ATV. It also includes basic maintenance and inspection procedures. If you have any questions regarding the operation or maintenance of your ATV, please consult a
Yamaha dealer.
AN IMPORTANT SAFETY MESSAGE:
● READ THIS MANUAL TOGETHER WITH TIPS FOR THE ATV RIDER CAREFULLY AND COMPLETELY BEFORE OPERATING YOUR ATV. MAKE SURE YOU UNDERSTAND ALL INSTRUCTIONS.
● PAY CLOSE ATTENTION TO THE WARNING AND NOTICE LABELS ON THE ATV.
● NEVER OPERATE AN ATV WITHOUT PROPER TRAINING OR INSTRUCTION. FREE TRAINING IS
AVAILABLE TO ANYONE WHO BUYS A NEW ATV. CALL 1-800-887-2887 FOR MORE INFORMATION.
● THIS ATV, AND ANY OTHER ATV OVER 90 cc, SHOULD NOT BE RIDDEN BY ANYONE UNDER 16
YEARS OF AGE.
● THIS ATV IS A HIGH-PERFORMANCE ATV FOR OFF-ROAD USE ONLY, FOR SPORT-TYPE RECREATIONAL AND COMPETITIVE USE BY EXPERIENCED OPERATORS.
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IMPORTANT MANUAL INFORMATION
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FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY OR DEATH.
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
WARNING
A WARNING indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
NOTICE
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
TIP
A TIP provides key information to make procedures easier or clearer.
* Product and specifications are subject to change without notice.
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IMPORTANT NOTICE
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Welcome to the Yamaha world of motor sports!
This ATV is designed and manufactured for OFF-ROAD use only. It is illegal and unsafe to operate this ATV
on any public street, road or highway.
This ATV complies with all applicable OFF-ROAD noise level and spark arrester laws and regulations in
effect at the time of manufacture.
Please check your local riding laws and regulations before operating this ATV.
EBU17402
YFM35XY
OWNER’S MANUAL
©2008 by Yamaha Motor Corporation, U.S.A.
1st edition, May 2008
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11626-22-44
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EWB00010
WARNING
Indicates a potential hazard that could result
in serious injury or death.
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TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ................................................ 4-1
Indicator lights and warning light ................ 4-2
Handlebar switches .................................... 4-3
Throttle lever .............................................. 4-4
Speed limiter .............................................. 4-4
Front brake lever .........................................4-5
Brake pedal and rear brake lever ...............4-6
Parking brake ..............................................4-7
Drive select lever ........................................4-7
Fuel tank cap ..............................................4-8
Fuel .............................................................4-8
Fuel cock ..................................................4-10
Starter (choke) ..........................................4-11
Seat ..........................................................4-12
Storage compartment ...............................4-13
Adjusting the front shock absorber
assemblies ..............................................4-14
Adjusting the rear shock absorber
assembly .................................................4-15
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Front and rear brakes .................................5-4
Throttle lever ...............................................5-5
Tires ............................................................5-6
Measuring the tire pressure ........................5-7
Tire wear limit .............................................5-8
Chassis fasteners .......................................5-8
Instruments, lights and switches .................5-8
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OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-6
Parking on a slope ..................................... 6-6
Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT............................................ 7-2
BE CAREFUL WHERE YOU RIDE........... 7-12
TURNING YOUR ATV .............................. 7-16
CLIMBING UPHILL ................................... 7-18
RIDING DOWNHILL.................................. 7-22
CROSSING A SLOPE............................... 7-24
CROSSING THROUGH SHALLOW
WATER ................................................... 7-26
RIDING OVER ROUGH TERRAIN ........... 7-28
SLIDING AND SKIDDING......................... 7-29
WHAT TO DO IF... .................................... 7-30
WHAT TO DO... ........................................ 7-30
PERIODIC MAINTENANCE AND MINOR
REPAIR ..........................................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance chart for the
emission control system ...........................8-3
General maintenance and lubrication
chart ..........................................................8-5
Removing and installing the panel ..............8-8
Checking the spark plug .............................8-9
Engine oil and oil filter cartridge ................8-11
Final gear oil .............................................8-15
Cleaning the air filter element ...................8-18
Cleaning the spark arrester ......................8-21
V-belt cooling duct check hose .................8-23
V-belt case drain plug ...............................8-23
Adjusting the carburetor ............................8-24
Adjusting the engine idling speed .............8-24
Adjusting the throttle cable free play .........8-25
Valve clearance ........................................8-26
Adjusting the drive select lever safety
system cable ...........................................8-26
Checking the front brake pads and rear
brake shoes ............................................8-26
Checking the brake fluid level ...................8-27
Changing the brake fluid ...........................8-28
Checking the front brake lever free play ...8-29
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Adjusting the brake pedal and rear brake
lever free play and checking the brake
pedal position ......................................... 8-29
Axle boots ................................................ 8-33
Brake light switches ................................. 8-33
Checking and lubricating the cables ........ 8-34
Checking and lubricating the front and
rear brake levers .................................... 8-34
Checking and lubricating the brake
pedal ...................................................... 8-35
Checking the wheel hub bearings ............ 8-35
Lubricating the steering shaft ................... 8-35
Battery ...................................................... 8-36
Replacing a fuse ...................................... 8-38
Replacing a headlight bulb ....................... 8-40
Adjusting a headlight beam ...................... 8-42
Replacing the tail/brake light bulb ............ 8-42
Removing a wheel .................................... 8-43
Installing a wheel ...................................... 8-43
Troubleshooting ....................................... 8-45
Troubleshooting chart .............................. 8-46
CLEANING AND STORAGE.......................... 9-1
Cleaning ..................................................... 9-1
Storage ....................................................... 9-2
SPECIFICATIONS .......................................10-1
CONSUMER INFORMATION.......................11-1
Identification numbers ...............................11-1
Noise regulation ........................................11-3
Maintenance record ..................................11-4
YAMAHA MOTOR CORPORATION,
U.S.A. ATV LIMITED WARRANTY .........11-5
YAMAHA EXTENDED SERVICE
(Y.E.S.) ...................................................11-7
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SAFETY INFORMATION
●
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AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.
An ATV handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine
maneuvers such as turning and riding on hills or
over obstacles, if you fail to take proper precautions.
SEVERE INJURY OR DEATH can result if you do
not follow these instructions:
● Read this manual and all labels carefully and follow the operating procedures described.
● Never operate an ATV without proper training or
instruction. Take a Training Course. Beginners
should receive training from a certified instructor. Contact an authorized ATV dealer or call 1800-887-2887 to find out about the training
courses nearest you.
● Always follow the age recommendation:
– A child under 16 years old should never operate an ATV with engine size greater than 90 cc.
●
●
●
●
●
●
●
1-1
Never allow a child under age 16 to operate an
ATV without adult supervision, and never allow
continued use of an ATV by a child if he or she
does not have the abilities to operate it safely.
Never carry a passenger on an ATV.
Always avoid operating an ATV on any paved
surfaces, including sidewalks, driveways, parking lots and streets.
Never operate an ATV on any public street, road
or highway, even a dirt or gravel one.
Never operate an ATV without wearing an approved motorcycle helmet that fits properly. You
should also wear eye protection (goggles or face
shield), gloves, boots, a long-sleeved shirt or a
jacket, and long pants.
Never consume alcohol or drugs before or while
operating this ATV.
Never operate at speeds too fast for your skills
or the riding conditions. Always go at a speed
that is proper for the terrain, visibility, operating
conditions, and your experience.
Never attempt wheelies, jumps, or other stunts.
1
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●
1
●
●
●
●
●
●
Always inspect your ATV each time you use it to
make sure it is in safe operating condition. Always follow the inspection and maintenance
procedures and schedules described in this
manual.
Always keep both hands on the handlebars and
both feet on the footboards of the ATV during
operation.
Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating the
ATV.
Never operate on excessively rough, slippery or
loose terrain until you have learned and practiced the skills necessary to control the ATV on
such terrain. Always be especially cautious on
these kinds of terrain.
Always follow proper procedures for turning as
described in this manual. Practice turning at low
speeds before attempting to turn at faster
speeds and never turn at excessive speeds.
Never operate the ATV on hills too steep for the
ATV or for your abilities. Practice on smaller hills
before attempting larger hills.
●
●
●
1-2
Always follow proper procedures for climbing
hills as described in this manual. Check the terrain carefully before you start up any hill. Never
climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the
throttle suddenly. Never go over the top of a hill
at high speed.
Always follow proper procedures for going down
hills and for braking on hills as described in this
manual. Check the terrain carefully before you
start down any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid going
down a hill at an angle that would cause the vehicle to lean sharply to one side. Go straight
down the hill where possible.
Always follow proper procedures for crossing
the side of a hill as described in this manual.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the
ATV. Never attempt to turn the ATV around on
any hill until you have mastered the turning technique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll
backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a
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●
●
●
●
●
hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to a side if
pointed straight uphill. Turn the ATV around and
remount, following the procedure described in
this manual.
Always check for obstacles before operating in a
new area.
Never attempt to operate over large obstacles,
such as large rocks or fallen trees. Always follow
proper procedures when operating over obstacles as described in this manual.
Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such as
ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.
Never operate an ATV in fast flowing water or in
water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.
Always be sure there are no obstacles or people
behind you when you operate in reverse. When
it is safe to proceed in reverse, go slowly.
● Always use the size and type of tires specified in
this manual.
● Always maintain proper tire pressure as described in this manual.
● Never modify an ATV through improper installation or use of accessories.
● Never exceed the stated load capacity for an
ATV. Cargo should be properly distributed and
securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Products Safety Commission at 1-800-638-2772, or the ATV Distributor’s
Safety Hotline at 1-800-852-5344.
1-3
1
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HOW TO AVOID THE HAZARD
If you should swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, seek medical help
immediately. If gasoline spills on your skin,
wash with soap and water. If gasoline spills
on your clothing, change your clothes.
EWB00021
WARNING
1
POTENTIAL HAZARD
Improper handling of gasoline.
WHAT CAN HAPPEN
Gasoline can catch fire and you could be
burned.
HOW TO AVOID THE HAZARD
Always turn off the engine when refueling.
Do not refuel right after the engine has been
running and is still very hot.
Do not spill gasoline on the engine or exhaust pipe/muffler when refueling.
Never refuel while smoking, or in the vicinity
of sparks, open flames, or other sources of
ignition such as the pilot lights of water
heaters and clothes dryers.
When transporting the ATV in another vehicle, be sure it is kept upright and that the
fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or
fuel tank.
WHAT CAN HAPPEN
Gasoline is poisonous and can cause injuries.
EWB00030
WARNING
POTENTIAL HAZARD
Starting or running the engine in a closed area.
1-4
U3D513E0.book Page 5 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
Exhaust fumes are poisonous and may
cause loss of consciousness and death
within a short time.
HOW TO AVOID THE HAZARD
Always operate your ATV in an area with adequate ventilation.
1
1-5
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LOCATION OF THE WARNING AND SPECIFICATION LABELS
2
2-1
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Read and understand all of the labels on your ATV. These labels contain important information for safe and
proper operation.
Never remove any labels from your ATV. If a label becomes difficult to read or comes off, request a replacement label from your Yamaha dealer.
3.6 psi, (25 kPa)
3.6 psi, (25 kPa)
3.2 psi, (22 kPa)
3.2 psi, (22 kPa)
220 lbs, (100 kg)
3D5-F816M-00
2-2
2
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2
2-3
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EBU17680
DESCRIPTION
EBU17690
EBU17700
Left view
Right view
3
1. Front shock absorber assembly spring preload adjusting
ring
2. Fuel cock
3. Air filter case
4. Fuses
5. Storage compartment and tool kit
6. Seat lock lever
7. Rear shock absorber assembly spring preload adjusting
ring
8. Engine oil filler cap
9. Oil filter cartridge
10.V-belt cooling duct check hose
1.
2.
3.
4.
Spark arrester
Tail/brake light
Spark plug
Front shock absorber assembly spring preload adjusting
ring
5. Rear brake light switch
6. Brake pedal
7. V-belt case
3-1
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EBU17712
Controls and instruments
3
1.
2.
3.
4.
5.
6.
7.
8.
Rear brake lever
Handlebar switches
Starter (choke)
Drive select lever
Main switch
Fuel tank cap
Front brake lever
Throttle lever
TIP
The ATV you have purchased may differ slightly
from the figures shown in this manual.
3-2
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INSTRUMENT AND CONTROL FUNCTIONS
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
EBU17760
4
Main switch
The positions of the main switch are as follows:
ON
All electrical systems are supplied with power. The
headlights and taillight come on when the light
switch is on, and the engine can be started. The
key cannot be removed.
1. Main switch
OFF
All electrical systems are off. The key can be removed.
4-1
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EBU17813
EBU26931
Indicator lights and warning light
Oil temperature warning light “ ”
This warning light comes on when the engine overheats. When this occurs, stop the engine as soon
as it is safe to do so, and allow it to cool.
The electrical circuit of the warning light can be
checked by turning the key to “ON”, with the engine
stop switch set to “ ”, and then pushing the start
switch.
If the warning light does not come on while the start
switch is being pushed, then go off after the start
switch is released, have a Yamaha dealer check
the electrical circuit.
If the warning light stays on, allow the engine to
cool. If the warning light stays on when the engine
is cool, have a Yamaha dealer check the electrical
circuit.
4
1. Reverse indicator light “R”
2. Neutral indicator light “N”
3. Oil temperature warning light “
”
EBU17830
ECB00010
Reverse indicator light “ ”
This indicator light comes on when the transmission is in the reverse position.
NOTICE
● The engine may overheat if the ATV is overloaded. In this case, reduce the load to specification.
● Start the engine after making sure that the
warning light is out. Continuous use while
the warning light is on may cause damage to
the engine.
EBU17860
Neutral indicator light “ ”
This indicator light comes on when the transmission is in the neutral position.
4-2
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EBU18061
EBU18100
Handlebar switches
Start switch “ ”
Push this switch to crank the engine with the starter.
ECB00050
NOTICE
See the starting instructions on page 6-1 prior
to starting the engine.
4
EBU18151
1. Light switch “
/
2. Engine stop switch “
3. Start switch “
”
Light switch “
/
/OFF”
Set this switch to “
” to turn on the low beams
and the taillight. Set the switch to “
” to turn on
the high beams and the taillight. Set the switch to
“OFF” to turn off all the lights.
/OFF”
/
”
ECB00040
NOTICE
Do not use the headlights with the engine
turned off for an extended period of time, otherwise the battery may discharge to the point
that the starter motor will not operate properly.
If this should happen, remove the battery and
recharge it.
EBU18080
Engine stop switch “ / ”
Set this switch to “ ” before starting the engine.
The engine stop switch controls the ignition and
stops the engine when it is running. Use this switch
to stop the engine in an emergency situation. The
engine will not start or run when this switch is set
to “ ”.
4-3
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EBU18270
EWB00200
Throttle lever
4
WARNING
Once the engine is running, movement of the throttle lever will increase the engine speed.
Regulate the speed of the ATV by varying the
throttle position. Because the throttle is springloaded, the ATV will decelerate, and the engine will
return to an idle any time the hand is removed from
the throttle lever.
POTENTIAL HAZARD
Malfunction of throttle.
WHAT CAN HAPPEN
The throttle could be hard to operate, making it difficult to speed up or slow down
when you need to. This could cause an accident.
HOW TO AVOID THE HAZARD
Check the operation of the throttle lever before you start the engine. If it does not work
smoothly, check for the cause. Correct the
problem before riding the ATV. Consult a
Yamaha dealer if you can’t find or solve the
problem yourself.
EBU18311
Speed limiter
Your ATV was delivered with an adjustable speed
limiter. The speed limiter keeps the throttle from
fully opening, even when the throttle lever is
pushed to the maximum.
1. Loosen the locknut.
2. To increase the maximum engine power available and the maximum speed of the ATV, turn
the adjusting screw in direction (a). To de-
1. Throttle lever
Before starting the engine, check the throttle to be
sure it is operating smoothly. Make sure it returns
to the idle position as soon as the lever is released.
4-4
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WHAT CAN HAPPEN
The throttle cable could be damaged. Improper throttle operation could result. You
could lose control, have an accident or be injured.
HOW TO AVOID THE HAZARD
Do not turn the adjusting screw out more
than 12 mm (0.47 in). Always make sure the
throttle lever free play is adjusted to 3.0–5.0
mm (0.12–0.20 in). (See page 8-25.)
crease the maximum engine power available
and the maximum speed of the ATV, turn the
adjusting screw in direction (b).
EBU18391
Front brake lever
The front brake lever is located on the right handlebar. To apply the front brake, pull the brake lever
toward the handlebar grip.
1. Locknut
2. Adjusting screw
3. No more than 12 mm (0.47 in)
3. Tighten the locknut.
EWB00190
WARNING
POTENTIAL HAZARD
Improper adjustment of the speed limiter
and throttle.
4-5
4
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4
1. Front brake lever
1. Brake pedal
EBU18442
Brake pedal and rear brake lever
The brake pedal is located on the right side of the
ATV and the rear brake lever is located on the left
handlebar. To apply the rear brake, push down on
the brake pedal or pull the brake lever toward the
handlebar grip.
1. Rear brake lever
4-6
U3D513E0.book Page 7 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
The ATV could start moving unexpectedly if
the parking brake is not applied before starting the engine. This could cause loss of control or a collision.
The brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which could
cause an accident. You could also wear out
the brakes prematurely.
HOW TO AVOID THE HAZARD
Always set the parking brake before starting
the engine.
Always be sure you have released the parking brake before you begin to ride.
EBU18450
Parking brake
Use the parking brake before starting the engine or
parking the ATV, especially on a slope. Apply the
rear brake lever and push down the lock plate to
apply the parking brake. Squeeze the rear brake
lever to release the parking brake.
EBU18581
Drive select lever
The drive select lever is used to shift your ATV into
the forward, neutral and reverse positions. See the
“Operating the drive select lever and driving in reverse” section on page 6-3 for the drive select lever
operation.
1. Parking brake lock plate
EWB00170
WARNING
POTENTIAL HAZARD
Improper use of the parking brake.
4-7
4
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4
1. Drive select lever
1. Fuel tank cap
EBU18720
EBU18730
Fuel tank cap
Fuel
Remove the fuel tank cap by turning it counterclockwise.
Make sure that there is sufficient fuel in the tank.
Fill the fuel tank to the bottom of the filler tube as
shown.
4-8
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ECB00070
NOTICE
Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts, such as the valves and piston
rings, as well as to the exhaust system.
Your Yamaha engine has been designed to use
regular unleaded gasoline with a pump octane
number [(R+M)/2] of 86 or higher, or a research octane number of 91 or higher. If knocking or pinging
occurs, use a different brand of gasoline or premium unleaded fuel. Unleaded fuel will give you longer spark plug life and reduced maintenance cost.
1. Fuel level
2. Fuel tank filler tube
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
14.5 L (3.83 US gal, 3.19 Imp.gal)
Fuel reserve amount:
4.5 L (1.19 US gal, 0.99 Imp.gal)
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol
containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing
methanol is not recommended by Yamaha because it can cause damage to the fuel system or
ATV performance problems.
4-9
4
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OFF
EWB00270
WARNING
4
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not to
spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed
securely.
Do not refuel right after the engine has been
running and is still very hot.
1. Arrow mark positioned over “OFF”
With the fuel cock lever in this position, fuel will not
flow. Always turn the fuel cock lever to this position
when the engine is not running.
EBU18820
Fuel cock
The fuel cock supplies fuel from the tank to the carburetor while also filtering it.
The fuel cock lever positions are explained as follows and shown in the illustrations.
4-10
U3D513E0.book Page 11 Monday, May 19, 2008 3:19 PM
ON
RES
4
1. Arrow mark positioned over “ON”
1. Arrow mark positioned over “RES”
With the fuel cock lever in this position, fuel flows
to the carburetor. Turn the fuel cock lever to this
position when starting the engine and riding.
This indicates reserve. With the fuel cock lever in
this position, the fuel reserve is made available.
Turn the fuel cock lever to this position if you run
out of fuel while riding. When this occurs, refuel as
soon as possible and be sure to turn the fuel cock
lever back to “ON”!
EBU18850
Starter (choke) “
”
Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter (choke).
Move the starter (choke) in direction (a) to turn on
the starter (choke).
4-11
U3D513E0.book Page 12 Monday, May 19, 2008 3:19 PM
Move the starter (choke) in direction (b) to turn off
the starter (choke).
See the “Starting a cold engine” section on page
6-1 for proper operation.
4
1. Seat
1. Starter (choke) “
”
EBU26981
Seat
To remove the seat
Push the seat lock lever backward and pull up the
seat at the rear.
1. Seat lock lever
4-12
U3D513E0.book Page 13 Monday, May 19, 2008 3:19 PM
When storing any documents in the storage compartment, be sure to wrap them in a plastic bag so
that they will not get wet. When washing the ATV,
be careful not to let any water enter the storage
compartment.
To install the seat
Fit the slot in the seat onto the projection on the
front cowling, insert the projections on the front of
the seat into the seat holders, and then push on the
seat at the rear.
ECB00130
TIP
Make sure that the seat is securely fitted.
NOTICE
Do not store metal or sharply edged objects,
like tools, in the storage compartment. If they
must be stored, wrap them in appropriate
cushion material to prevent damaging the storage compartment.
1. Slot
2. Projection
3. Seat holder
EBU26551
Storage compartment
1. Storage compartment
The storage compartment is located under the
seat. (See page 4-12.)
●
4-13
Do not exceed the load limit of 2.0 kg (4 lb)
for the storage compartment.
4
U3D513E0.book Page 14 Monday, May 19, 2008 3:19 PM
●
Turn the adjusting ring in direction (a) to increase
the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring
preload and thereby soften the suspension.
Do not exceed the maximum load of 100.0 kg
(220 lb) for the ATV.
TIP
Drain plugs are fitted at the bottom of the storage
compartment. If any water collects in the storage
compartment, remove the drain plugs, drain the
water, and then install the drain plugs.
4
1. Spring preload adjusting ring
2. Position indicator
TIP
A special wrench can be obtained at a Yamaha
dealer to make this adjustment.
1. Storage compartment drain plug
EBU18981
Adjusting the front shock absorber assemblies
The spring preload can be adjusted to suit the rider’s weight and the riding conditions.
Adjust the spring preload as follows.
4-14
U3D513E0.book Page 15 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
Uneven adjustment can cause poor handling
and loss of stability, which could lead to an
accident.
HOW TO AVOID THE HAZARD
Always adjust the shock absorber assemblies on the left and right side to the same
setting.
EBU19021
Adjusting the rear shock absorber assembly
1. Special wrench
The spring preload can be adjusted to suit the rider’s weight and the riding conditions.
Adjust the spring preload as follows.
Turn the adjusting ring in direction (a) to increase
the spring preload and thereby harden the suspension, and in direction (b) to decrease the spring
preload and thereby soften the suspension.
Spring preload setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
5
EWB00350
WARNING
POTENTIAL HAZARD
Improper shock absorber assembly adjustment.
4-15
4
U3D513E0.book Page 16 Monday, May 19, 2008 3:19 PM
4
1. Spring preload adjusting ring
2. Position indicator
1. Special wrench
Spring preload setting:
Minimum (soft):
1
Standard:
2
Maximum (hard):
5
TIP
A special wrench can be obtained at a Yamaha
dealer to make this adjustment.
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
4-16
U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM
EBU19200
PRE-OPERATION CHECKS
EBU19213
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
EWB00470
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.
TIP
The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodic
maintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM
Fuel
ROUTINE
• Check fuel level in fuel tank, and add recommended fuel if necessary.
• Check fuel line for leakage. Correct if necessary.
5-1
PAGE
4-8, 5-3
5
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
ITEM
Engine oil
Final gear oil
Front brake
5
Rear brake
Throttle lever
Control cables
Wheels and tires
Brake pedal
Brake levers
Axle boots
Chassis fasteners
Instruments, lights and
switches
ROUTINE
• Check oil level in engine, and add recommended oil to specified level if necessary.
• Check ATV for oil leakage. Correct if necessary.
• Check ATV for oil leakage. Correct if necessary.
• Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear, and replace if necessary.
• Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.
• Check hydraulic system for leakage. Correct if necessary.
• Check operation, and correct if necessary.
• Lubricate cables if necessary.
• Check lever and pedal free play, and adjust if necessary.
• Make sure that operation is smooth. Lubricate cable and lever housing if necessary.
• Check cable free play, and adjust if necessary.
• Make sure that operation is smooth. Lubricate if necessary.
• Check wheel condition, and replace if damaged.
• Check tire condition and tread depth. Replace if necessary.
• Check air pressure. Correct if necessary.
• Make sure that operation is smooth. Lubricate pedal pivoting point if
necessary.
• Make sure that operation is smooth. Lubricate lever pivoting points if
necessary.
• Check for cracks or damage, and replace if necessary.
• Make sure that all nuts, bolts and screws are properly tightened.
• Check operation, and correct if necessary.
5-2
PAGE
5-3, 8-11
5-3, 8-15
5-4, 8-26, 8-27, 8-29
5-4, 8-26, 8-29
5-5, 8-25
8-34
5-6, 5-7, 5-8
8-35
8-34
8-33
5-8
5-8
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
EBU19530
EBU19590
Fuel
Final gear oil
Make sure that there is sufficient fuel in the tank.
(See page 4-8.)
Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-15.)
EWB00500
WARNING
POTENTIAL HAZARD
Improper care when refueling.
WHAT CAN HAPPEN
Fuel can spill, which can cause a fire and severe injury.
Fuel expands when it heats up. If the fuel
tank is overfilled, fuel could spill out due to
heat from the engine or the sun.
HOW TO AVOID THE HAZARD
Do not overfill the fuel tank. Be careful not to
spill fuel, especially on the engine or exhaust pipe. Wipe up any spilled fuel immediately. Be sure the fuel tank cap is closed
securely.
Do not refuel right after the engine has been
running and is still very hot.
5
EBU19560
Engine oil
Make sure that the engine oil is at the specified level. Add oil as necessary. (See page 8-11.)
5-3
U3D513E0.book Page 4 Monday, May 19, 2008 3:19 PM
lever moves slowly inward, there may be a leak in
the brake system. If there is any leakage, the brake
system should be checked by a Yamaha dealer.
EBU27660
Front and rear brakes
5
Brake levers and brake pedal
● Check that there is no free play in the front brake
lever. If there is free play, have a Yamaha dealer
check the brake system.
● Check for correct free play in the rear brake lever
and brake pedal. If the free play is incorrect, adjust it. (See page 8-29.)
● Check operation of the levers and pedal. They
should move smoothly and there should be a
firm feeling when the brake is applied. If not,
have a Yamaha dealer check them.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, check
the brake pads and shoes for wear. (See page
8-26.)
EWB00540
WARNING
POTENTIAL HAZARD
Riding with improperly operating brakes.
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD
Always check the brakes at the start of every
ride. Do not ride the ATV if you find any problem with the brakes. If a problem cannot be
corrected by the adjustment procedures provided in this manual, have a Yamaha dealer
check for the cause.
Brake fluid level (front brake)
Check the brake fluid level. Add fluid if necessary.
(See page 8-27.)
Recommended brake fluid:
DOT 4
Brake fluid leakage (front brake)
Check to see if any brake fluid is leaking out of the
hose, joint or brake fluid reservoir of the front
brake. Apply the brake firmly for one minute. If the
5-4
U3D513E0.book Page 5 Monday, May 19, 2008 3:19 PM
EBU19761
Throttle lever
Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary.
5
5-5
U3D513E0.book Page 6 Monday, May 19, 2008 3:19 PM
EBU19802
Tires
EWB00552
WARNING
5
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire
pressure, may cause loss of control, increasing your risk of accident.
HOW TO AVOID THE HAZARD
● The tires listed below have been approved
by Yamaha Motor Manufacturing Corporation of America for this model. Other tire
combinations are not recommended.
Front:
Manufacturer/model:
MAXXIS/M937
Size:
AT23 x 8-12
Type:
Tubeless
●
5-6
Rear:
Manufacturer/model:
MAXXIS/M938
Size:
AT23 x 10-12
Type:
Tubeless
The tires should be set to the recommended pressure:
Recommended tire pressure:
Front:
25.0 kPa (0.250 kgf/cm², 3.6 psi)
Rear:
25.0 kPa (0.250 kgf/cm², 3.6 psi)
• Check and adjust tire pressures when
the tires are cold.
• Tire pressures must be equal on both
sides.
U3D513E0.book Page 7 Monday, May 19, 2008 3:19 PM
●
●
●
Tire pressure below the minimum specified could cause the tire to dislodge from
the rim under severe riding conditions.
Minimum tire pressure:
Front:
22.0 kPa (0.220 kgf/cm², 3.2 psi)
Rear:
22.0 kPa (0.220 kgf/cm², 3.2 psi)
Use no more than the following pressures
when seating the tire beads.
Maximum tire seating pressure:
Front:
250 kPa (2.5 kgf/cm², 36 psi)
Rear:
250 kPa (2.5 kgf/cm², 36 psi)
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very
slowly and carefully.
TIP
The low-pressure tire gauge is included as standard equipment. Make two measurements of the
tire pressure and use the second reading. Dust or
dirt in the gauge could cause the first reading to be
incorrect.
5
1. Low-pressure tire gauge
EBU19821
Measuring the tire pressure
Set the tire pressure when the tires are cold. Set
the tire pressures to the following specifications:
Use the low-pressure tire gauge.
5-7
U3D513E0.book Page 8 Monday, May 19, 2008 3:19 PM
5
Recommended pressure:
Front
25.0 kPa (0.250 kgf/cm², 3.6 psi)
Rear
25.0 kPa (0.250 kgf/cm², 3.6 psi)
Minimum:
Front
22.0 kPa (0.220 kgf/cm², 3.2 psi)
Rear
22.0 kPa (0.220 kgf/cm², 3.2 psi)
1. Tire wear limit
EBU19830
Tire wear limit
EBU19840
Replace the tire when the tire groove decreases to
3 mm (0.12 in).
Chassis fasteners
Make sure that all nuts, bolts and screws are properly tightened.
EBU19850
Instruments, lights and switches
Check that all instruments, lights and switches are
working properly. Correct if necessary.
5-8
U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM
EBU19870
OPERATION
EBU26940
EWB00010
Starting a cold engine
WARNING
Indicates a potential hazard that could result in
serious injury or death.
EWB00620
WARNING
POTENTIAL HAZARD
Frozen control cables in cold weather.
WHAT CAN HAPPEN
You could be unable to control the ATV,
which could lead to an accident or collision.
HOW TO AVOID THE HAZARD
When riding in cold weather, always make
sure all control cables work smoothly before
you begin riding.
EBU19890
EWB00610
WARNING
POTENTIAL HAZARD
Operating ATV without being familiar with all
controls.
WHAT CAN HAPPEN
Loss of control, which could cause an accident or injury.
HOW TO AVOID THE HAZARD
Read the Owner’s Manual carefully. If there is
a control or function you do not understand,
ask your Yamaha dealer.
ECB00150
NOTICE
See the “Engine break-in” section on page 6-5
prior to operating the engine for the first time.
1. Set the parking brake.
2. Turn the fuel cock to “ON”.
3. Turn the main switch to “ON” and the engine
stop switch to “ ”.
6-1
6
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
Ambient temp./starter (choke) position
4. Shift the drive select lever into the neutral position. The neutral indicator light should come
on. If the indicator light does not come on,
have a Yamaha dealer check the electrical circuit.
6
TIP
The engine can be started under the following conditions:
● The drive select lever is in the neutral position.
● The rear brake lever is applied with the drive select lever in any position. However, it is recommended to shift into the neutral position before
starting the engine.
1.
2.
3.
4.
5. Use the starter (choke) in reference to the figure:
Position (1):
Cold engine start with ambient temperature
below 5 °C (40 °F).
Position (2):
Cold engine start with ambient temperature
between 0 °C (30 °F) and 30 °C (90 °F).
Position (3):
Cold engine start with ambient temperature
above 25 °C (80 °F).
Fully open
Half open
Closed
Starter (choke)
6. Completely close the throttle lever and start
the engine by pushing the start switch.
TIP
If the engine fails to start, release the start switch,
then push it again. Pause a few seconds before
the next attempt. Each cranking should be as short
as possible to preserve battery energy. Do not
crank the engine more than 10 seconds on each
attempt.
6-2
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
7. If the engine is started with the starter (choke)
in position (1), the starter (choke) should be
returned to position (2) to warm up the engine.
If the engine is started with the starter (choke)
in position (2), keep the starter (choke) in this
position to warm up the engine.
EBU20370
Operating the drive select lever and
driving in reverse
ECB00170
NOTICE
Before shifting, stop the ATV, otherwise the
transmission may be damaged.
ECB00160
NOTICE
For maximum engine life, always warm the engine up before starting off. Never accelerate
hard when the engine is cold!
Shifting: Forward
1. Bring the ATV to a complete stop.
2. Shift from neutral to forward and vice versa by
moving the drive select lever along the shift
guide.
8. Continue warming up the engine until it idles
smoothly, then return the starter (choke) to
position (3) before riding.
TIP
Make sure that the drive select lever is completely
shifted into position.
TIP
The engine is warm when it responds normally to
the throttle with the starter (choke) turned off.
EBU20291
Starting a warm engine
Follow the same procedure as for starting a cold
engine, with the exception that the starter (choke)
is not required when the engine is warm. Instead,
start the engine with the throttle slightly open.
6-3
6
U3D513E0.book Page 4 Monday, May 19, 2008 3:19 PM
TIP
When in reverse, the reverse indicator light should
come on. If the indicator light does not come on,
have a Yamaha dealer check the electrical circuit.
F 2
N 3
R 4
F 2
N 3
6
1.
2.
3.
4.
Drive select lever
F (Forward)
N (Neutral)
R (Reverse)
R 4
3. Open the throttle lever gradually.
1.
2.
3.
4.
Shifting: Reverse
1. Bring the ATV to a complete stop.
2. Apply the brake pedal.
3. Shift from neutral to reverse and vice versa by
moving the drive select lever along the shift
guide.
Drive select lever
F (Forward)
N (Neutral)
R (Reverse)
4. Check behind for people or obstacles, and
then release the brake pedal.
5. Open the throttle lever gradually and continue
to watch to the rear while backing.
6-4
U3D513E0.book Page 5 Monday, May 19, 2008 3:19 PM
Since the engine is brand new, do not put an excessive load on it for the first 320 km (200 mi) or 20
hours. The various parts in the engine wear and
polish themselves to the correct operating clearances. During this period, prolonged full-throttle
operation or any condition that might result in engine overheating must be avoided.
EWB00670
WARNING
POTENTIAL HAZARD
Improper operation in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or even a person
behind you, resulting in serious injury.
HOW TO AVOID THE HAZARD
When you shift into reverse, make sure there
are no people or obstacles behind you.
When it is safe to proceed, go slowly.
0–160 km (0–100 mi) or 0–10 hours
Avoid prolonged operation above 1/2 throttle. Vary
the speed of the ATV regularly. Do not operate it at
one set throttle position.
EBU20682
160–320 km (100–200 mi) or 10–20 hours
Avoid prolonged operation above 3/4 throttle. Rev
the engine freely, but do not use full throttle at any
time.
Engine break-in
TIP
● For ATVs equipped with an odometer or an hour
meter, follow the figures given in km (mi) or the
figures given in hours.
● For ATVs not equipped with an odometer or
hour meter, follow the figures given in hours.
320 km (200 mi) or 20 hours and beyond
The ATV can now be operated normally.
ECB00220
NOTICE
If any engine trouble should occur during the
engine break-in period, immediately have a
Yamaha dealer check the ATV.
There is never a more important period in the life of
your engine than the first 320 km (200 mi) or 20
hours of riding. For this reason, you should read
the following material carefully.
6-5
6
U3D513E0.book Page 6 Monday, May 19, 2008 3:19 PM
1. Bring the ATV to a stop by applying the brakes
in the forward position.
2. Stop the engine.
3. With the rear brake lever and pedal applied,
apply the parking brake, and then slowly release the brake pedal.
EBU20700
Parking
When parking the ATV, stop the engine, shift the
drive select lever into the forward position, apply
the parking brake, and then turn the fuel cock to
“OFF”.
EBU20750
Parking on a slope
EWB00760
WARNING
6
POTENTIAL HAZARD
Parking on a hill or other incline.
WHAT CAN HAPPEN
The ATV could roll out of control, increasing
the chance of an accident.
HOW TO AVOID THE HAZARD
Avoid parking on hills or other inclines. If
you must park on an incline, place the ATV
transversely across the incline, shift the
drive select lever to the forward position,
stop the engine, apply the parking brake,
and then block the front and rear wheels
with rocks or other objects.
Do not park the ATV at all on hills that are so
steep you could not walk up them easily.
EBU20910
Accessories and loading
EBU20920
Accessories
Accessories can affect the handling and control of
your ATV. Keep the following in mind when considering an accessory or operating an ATV which has
accessories.
6-6
U3D513E0.book Page 7 Monday, May 19, 2008 3:19 PM
●
●
●
●
Choose only accessories designed for your
ATV. Your Yamaha dealer has a variety of genuine Yamaha accessories. Other accessories
may also be available on the market. However,
it is not possible for Yamaha to test all nonYamaha accessories, nor control over their quality or suitability. Choose a genuine Yamaha accessory, or one that is equivalent in design and
quality.
Accessories should be rigidly and securely
mounted. An accessory which can shift position
or come off while you are riding could affect your
ability to control the ATV.
Do not mount an accessory where it could interfere with your ability to control the ATV. Examples include (but are not limited to) a heavy or
bulky object attached to the handlebars which
could make steering difficult, an accessory that
limits your ability to move around on the seat, or
one that limits your view.
Use extra caution when riding an ATV with accessories. The ATV may handle differently than
it does without accessories.
EBU26380
Loading
As originally equipped, this ATV is not designed to
carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good
judgment as the stability and handling of an ATV
can be changed. When adding accessories, keep
the following points in mind:
● Never exceed the weight limits shown. An overloaded ATV can be unstable.
MAXIMUM LOADING LIMIT
ATV loading limit (total weight of rider, cargo,
accessories, and tongue):
100.0 kg (220 lb)
Storage compartment:
2.0 kg (4 lb)
●
●
6-7
If you are carrying cargo and towing a trailer, include the tongue weight in the maximum ATV
load limit.
Load cargo on the carriers as close to the center
of the ATV as possible. Put cargo at the rear of
the front carrier, at the front of the rear carrier,
and center it.
6
U3D513E0.book Page 8 Monday, May 19, 2008 3:19 PM
●
●
●
●
●
6
●
Tie down cargo securely to the carriers. Make
sure cargo in the trailer cannot move around. A
shifting load can cause an accident.
Make sure the load does not interfere with controls or your ability to see where you are going.
Ride more slowly than you would without a load.
The more weight you carry, the slower you
should go.
Allow more braking distance. A heavier ATV
takes longer to stop.
Avoid making sharp turns unless at very slow
speeds.
Avoid hills and rough terrain. Choose terrain
carefully. Added weight affects the stability and
handling of the ATV.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
EWB00750
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing
cargo improperly.
WHAT CAN HAPPEN
Could cause changes in ATV handling which
could lead to an accident.
6-8
U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM
EBU21131
RIDING YOUR ATV
7
7-1
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
RIDE WITH CARE AND GOOD JUDGEMENT
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
Get training if you are inexperienced.
Beginners should get training from a certified instructor.
Become familiar with this ATV at slow speeds first,
even if you are an experienced operator. Do not attempt to operate at maximum performance until
you are totally familiar with the ATV’s handling and
performance characteristics.
EBU26962
7
GETTING TO KNOW YOUR ATV
This ATV is intended for recreational use by experienced operators only. Even if you are an experienced operator of all other all terrain ATVs or
motorcycles, riding the ATV requires special skills
acquired through practice. Take your time to fully
learn techniques before attempting more difficult
maneuvers.
Riding your new ATV can be a very enjoyable activity, providing you with hours of pleasure. But it is
essential to familiarize yourself with the operation
of the ATV to achieve the skill necessary to enjoy
riding safely. Before you begin to ride, be sure you
have read this Owner’s Manual completely and understand the operation of the controls. Pay particular attention to the safety information on pages
1-1–1-5. Please also read all notice and warning
labels on your ATV.
EWB01280
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if
the operator does not know how to operate
the ATV properly in different situations and
on different types of terrain.
7-2
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators
should complete the certified training
course offered by Yamaha. They should then
regularly practice the skills learned in the
course and the operating techniques described in this Owner’s Manual. For more information about the training course, contact
an authorized ATV dealer or call 1-800-8872887.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.
HOW TO AVOID THE HAZARD
A child under 16 should never operate an
ATV with engine size greater than 90 cc.
Riding your ATV requires skills acquired
through practice over a period of time.
Take the time to learn the basic techniques well
before attempting more difficult maneuvers.
7
Not recommended for children under 16 years
of age.
EWB00901
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations
for this ATV.
7-3
U3D513E0.book Page 4 Monday, May 19, 2008 3:19 PM
This ATV is designed to carry operator and cargo only – passengers prohibited.
EWB00910
WARNING
7
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and
control this ATV. Could cause an accident,
resulting in harm to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to
allow the operator to shift position as needed during operation. It is not for carrying
passengers.
7-4
U3D513E0.book Page 5 Monday, May 19, 2008 3:19 PM
Apparel
HOW TO AVOID THE HAZARD
Always wear an approved motorcycle helmet
that fits properly.
You should also wear:
● eye protection (goggles or face shield)
● gloves
● boots
● long-sleeved shirt or jacket
● long pants
EWB00920
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved motorcycle helmet, eye protection
and protective clothing.
WHAT CAN HAPPEN
Operating without an approved motorcycle
helmet increases your chances of a severe
head injury or death in the event of an accident.
Operating without eye protection can result
in an accident and increases your chances
of a severe injury in the event of an accident.
Operating without protective clothing increases your chances of severe injury in the
event of an accident.
7
1.
2.
3.
4.
5.
7-5
Protective clothing
Goggles
Gloves
Boots
Helmet
U3D513E0.book Page 6 Monday, May 19, 2008 3:19 PM
Do not operate after consuming alcohol or
drugs.
The operator’s performance capability is reduced
by the influence of alcohol or drugs.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or
while driving this ATV.
Pre-operation checks
Always perform the pre-operation checks listed on
page 5-1 before riding for proper care of the ATV
and to ensure safety.
EWB00940
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use
it to make sure the ATV is in safe operating
condition.
Always follow the inspection and maintenance procedures and schedules described
in the Owner’s Manual.
7
EWB00930
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol
or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
7-6
U3D513E0.book Page 7 Monday, May 19, 2008 3:19 PM
Do not operate at speeds too fast for your skills
or the conditions.
EWB00950
WARNING
EWB00960
POTENTIAL HAZARD
Operating this ATV with improper tires, or
with improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV with improper or uneven tire
pressure, may cause loss of control, increasing your risk of an accident.
HOW TO AVOID THE HAZARD
Always use the size and type tires specified
in the Owner’s Manual for this ATV on page
5-6.
Always maintain proper tire pressure as described in the Owner’s Manual on page 5-7.
WARNING
POTENTIAL HAZARD
Operating this ATV at speeds too fast for
your skills or the conditions.
WHAT CAN HAPPEN
Increases your chances of losing control of
the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always go at a speed that is proper for the
terrain, visibility and operating conditions,
and your experience.
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
7-7
7
U3D513E0.book Page 8 Monday, May 19, 2008 3:19 PM
Loading and accessories
As originally equipped, this ATV is not designed to
carry cargo or tow a trailer. If you choose to add accessories so that you can carry cargo or tow a trailer, you must use common sense and good
judgment.
Use extra caution when riding the ATV with additional loads, such as accessories or cargo. The
ATV’s handling may be adversely affected. Reduce your speed when adding additional loads.
Speed limiter
For riders less experienced with this model, the
throttle lever housing is equipped with a speed limiter. The speed limiter keeps the throttle from fully
opening, even when the throttle lever is pushed to
the maximum. Turning in the adjusting screw limits
the maximum engine power available and decreases the maximum speed of the ATV. Turning
in the adjusting screw decreases top speed, and
turning it out increases top speed. (See page 4-4.)
MAXIMUM LOADING LIMIT
ATV loading limit (total weight of cargo, rider,
accessories, and tongue):
100.0 kg (220 lb)
Storage compartment:
2.0 kg (4 lb)
7
EWB00970
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing
cargo improperly.
WHAT CAN HAPPEN
Could cause changes in ATV handling which
could lead to an accident.
1. Adjusting screw
7-8
U3D513E0.book Page 9 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for
this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
Always follow the instructions in your Owner’s Manual for carrying cargo or pulling a
trailer.
During operation
Always keep your feet on the footboards during operation, otherwise they may contact the rear
wheels.
7
7-9
U3D513E0.book Page 10 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies or
jumps. Don’t try to show off.
EWB00980
WARNING
7
POTENTIAL HAZARD
Removing hands from handlebars or feet
from footboards during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce
your ability to control the ATV or could
cause you to lose your balance and fall off of
the ATV. If you remove a foot from a footboard, your foot or leg may come into contact with the rear wheels, which could injure
you or cause an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars
and both feet on the footboards of your ATV
during operation.
Avoid wheelies and jumping. You may lose control
of the ATV or overturn.
EWB00990
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps, and other
stunts.
7-10
U3D513E0.book Page 11 Monday, May 19, 2008 3:19 PM
Modifications
EWB01000
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this ATV may cause changes in
handling which in some situations could
lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of accessories. All parts
and accessories added to this ATV should
be genuine Yamaha or equivalent components designed for use on this ATV and
should be installed and used according to
instructions. If you have questions, consult
an authorized ATV dealer.
7
7-11
U3D513E0.book Page 12 Monday, May 19, 2008 3:19 PM
Exhaust system
The exhaust system on the ATV is very hot during
and following operation. To prevent burns, avoid
touching the exhaust system. Park the ATV in a
place where pedestrians or children are not likely
to touch it.
EWB01010
WARNING
7
POTENTIAL HAZARD
Hot exhaust system.
WHAT CAN HAPPEN
Dry grass or brush or other combustible material accumulated around the engine area
could catch fire.
Someone touching the exhaust system during or after operation could be burned.
HOW TO AVOID THE HAZARD
Do not operate, idle, or park the ATV in dry
grass or other dry ground cover.
Keep the engine area free of dry grass,
brush, or other combustible material.
Do not touch the hot exhaust system.
Do not park the ATV in a place where others
might be likely to touch it.
BE CAREFUL WHERE YOU RIDE
This ATV is designed for off-road use only. Riding
on paved surfaces can cause loss of control.
EWB01020
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces.
WHAT CAN HAPPEN
ATVs are designed for off-road use only.
Paved surfaces may seriously affect handling and control of the ATV, and may cause
the ATV to go out of control.
7-12
U3D513E0.book Page 13 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Always avoid paved surfaces, including
sidewalks, driveways, parking lots and
streets.
EWB01030
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads
or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street,
road or highway, even a dirt or gravel one. In
many states it is illegal to operate ATVs on
public streets, roads and highways.
7
Do not ride on any public road, street, or highway.
Riding on public roads can result in collisions with
other vehicles.
7-13
U3D513E0.book Page 14 Monday, May 19, 2008 3:19 PM
Know the terrain where you ride. Ride cautiously in
unfamiliar areas. Stay alert for holes, rocks, or
roots in the terrain, and other hidden hazards
which may cause the ATV to upset.
EWB01040
WARNING
7
POTENTIAL HAZARD
Failure to use extra care when operating this
ATV on unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or
holes, without enough time to react. Could
result in the ATV overturning or going out of
control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to
changing terrain conditions when operating
the ATV.
EWB01050
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on
excessively rough, slippery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or ATV control,
which could result in an accident, including
an overturn.
7-14
U3D513E0.book Page 15 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose terrain until you have learned
and practiced the skills necessary to control
the ATV on such terrain. Always be especially cautious on these kinds of terrain.
7
EWB01060
WARNING
POTENTIAL HAZARD
Operating in areas where you might not be
seen by other off-road vehicles.
WHAT CAN HAPPEN
You could be in a collision. You could be injured.
HOW TO AVOID THE HAZARD
Always mount a caution flag on the ATV to
make you more visible. Watch carefully for
other vehicles.
When riding in an area where you might not easily
be seen, such as desert terrain, mount a caution
flag on the ATV. DO NOT use the flag pole bracket
as a trailer hitch.
7-15
U3D513E0.book Page 16 Monday, May 19, 2008 3:19 PM
hot when riding and afterwards; do not allow skin
or clothing to come in contact with these components.
With the engine idling, return the starter (choke) to
the closed position and shift the drive select lever
into the forward position, then release the parking
brake. Apply the throttle slowly and smoothly. The
centrifugal clutch will engage and you will start to
accelerate. If the throttle is applied too abruptly, the
front wheels may lift off the ground, resulting in a
loss of directional control. Avoid higher speeds until you are thoroughly familiar with the operation of
your ATV.
When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. Improper use of the brakes can cause the tires to lose
traction, reducing control and increasing the possibility of an accident.
Do not ride in areas posted “no trespassing”.
Do not ride on private property without getting permission.
7
Select a large, flat area off-road to become familiar
with your ATV. Make sure that this area is free of
obstacles and other riders. You should practice
control of the throttle, brakes, and turning techniques in this area before trying more difficult terrain. Always avoid riding on paved surfaces: the
ATV is designed for off-road use only, and handling maneuvers are more difficult to perform on
pavement.
Set the parking brake and follow the instruction on
page 6-1 to start the engine. Once it has warmed
up you are ready to begin riding your ATV. Remember that the engine and exhaust pipe will be
TURNING YOUR ATV
To achieve maximum traction while riding off-road,
the two rear wheels are mounted solidly on one
axle and turn together at the same speed. Therefore, unless the wheel on the inside of the turn is allowed to slip or lose some traction, the ATV will
resist turning. A special turning technique must be
7-16
U3D513E0.book Page 17 Monday, May 19, 2008 3:19 PM
used to allow the ATV to make turns quickly and
easily. It is essential that this skill be learned first at
low speed.
EWB01080
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a collision or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning
as described in this Owner’s Manual. Practice turning at low speeds before attempting
to turn at faster speeds. Do not turn at
speeds too fast for your skills or the conditions.
1. Lean towards inside of turn.
2. Support your weight on the outer footboard.
This procedure should be practiced at slow speed
many times in a large off-road area with no obstacles. If an incorrect technique is used, your ATV
may continue to go straight. If the ATV doesn’t
turn, come to a stop and then practice the procedure again. If the riding surface is slippery or loose,
it may help to position more of your weight over the
front wheels by moving forward on the seat.
Once you have learned this technique, you should
be able to perform it at higher speeds or in tighter
curves.
As you approach a curve, slow down and begin to
turn the handlebars in the desired direction. As you
do so, put your weight on the footboard to the outside of the turn (opposite your desired direction)
and lean your upper body into the turn. Use the
throttle to maintain an even speed through the turn.
This maneuver will let the wheel on the inside of
the turn slip slightly, allowing the ATV to make the
turn properly.
7-17
7
U3D513E0.book Page 18 Monday, May 19, 2008 3:19 PM
Improper riding procedures such as abrupt throttle
changes, excessive braking, incorrect body movements, or too much speed for the sharpness of the
turn may cause the ATV to tip. If the ATV begins to
tip over to the outside while negotiating a turn, lean
more to the inside. It may also be necessary to
gradually let off on the throttle and steer to the outside of the turn to avoid tipping over.
Remember: Avoid higher speeds until you are
thoroughly familiar with the operation of your ATV.
7
WHAT CAN HAPPEN
The ATV can overturn more easily on extremely steep hills than on level surfaces or
small hills.
HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep for
the ATV or for your abilities. Practice on
smaller hills before attempting large hills.
It is important when climbing a hill to make sure
that your weight is transferred forward on the ATV.
This can be accomplished by leaning forward and,
on steeper inclines, standing on the footboards
and leaning forward over the handlebars.
CLIMBING UPHILL
Use proper riding techniques to avoid ATV overturns on hills. Be sure that you can maneuver your
ATV well on flat ground before attempting any incline and then practice riding first on gentle slopes.
Try more difficult climbs only after you have developed your skill. In all cases avoid inclines with slippery or loose surfaces, or obstacles that might
cause you to lose control.
EWB01180
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
EWB01090
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
7-18
U3D513E0.book Page 19 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as described in this Owner’s Manual.
Always check the terrain carefully before
you start up any hill.
Never climb hills with excessively slippery
or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly. The ATV
could flip over backwards.
Never go over the top of any hill at high
speed. An obstacle, a sharp drop, or another
vehicle or person could be on the other side
of the hill.
7
7-19
U3D513E0.book Page 20 Monday, May 19, 2008 3:19 PM
If you are climbing a hill and you find that you have
not properly judged your ability to make it to the
top, you should turn the ATV around while you still
have forward motion (provided you have the room
to do so) and go down the hill.
When crossing the side of a hill:
Always follow proper procedures as described in the Owner’s Manual.
Avoid hills with excessively slippery or loose
surfaces.
Shift your weight to the uphill side of the
ATV.
EWB01190
WARNING
7
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any
hill until you have mastered the turning technique as described in the Owner’s Manual
on level ground. Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible.
If your ATV has stalled or stopped and you believe
you can continue up the hill, restart carefully to
make sure you do not lift the front wheels which
could cause you to lose control. If you are unable
to continue up the hill, dismount the ATV on the uphill side. Physically turn the ATV around and then
descend the hill.
7-20
U3D513E0.book Page 21 Monday, May 19, 2008 3:19 PM
If you start to roll backwards, DO NOT apply the
rear brake to stop or try to put the ATV in gear. The
ATV could easily tip over backwards. Instead, apply the front brake gradually, or dismount the ATV
immediately on the uphill side.
If you begin rolling backwards:
● Keep weight uphill.
● Never apply the rear brake while rolling
backwards. Apply the front brake.
● When fully stopped, apply the rear brake
as well, and then lock the parking brake.
Dismount on uphill side or to a side if pointed straight uphill. Turn the ATV around and
remount, following the procedure described
in the Owner’s Manual.
EWB01261
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climbing a hill.
WHAT CAN HAPPEN
Could result in ATV overturning.
HOW TO AVOID THE HAZARD
Maintain a steady speed when climbing a
hill.
If you lose all forward speed:
● Keep weight uphill.
● Apply the brakes.
● Apply the parking brake after you are
stopped.
7
7-21
U3D513E0.book Page 22 Monday, May 19, 2008 3:19 PM
7
RIDING DOWNHILL
When riding your ATV downhill, shift your weight
as far to the rear and uphill side of the ATV as possible. Move back on the seat and sit with your arms
straight. Improper braking may cause a loss of
traction.
Use caution while descending a hill with loose or
slippery surfaces. Braking ability and traction may
be adversely affected by these surfaces. Improper
braking may also cause a loss of traction.
Whenever possible, ride your ATV straight downhill. Avoid sharp angles which could allow the ATV
to tip or roll over. Carefully choose your path and
ride no faster than you will be able to react to obstacles which may appear.
HOW TO AVOID THE HAZARD
Always follow proper procedures for going
down hills as described in this Owner’s Manual.
Note: a special technique is required when
braking as you go down a hill.
Always check the terrain carefully before
you start down any hill.
Shift your weight backward.
Never go down a hill at high speed.
Avoid going down a hill at an angle that
would cause the ATV to lean sharply to one
side. Go straight down the hill where possible.
EWB01130
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
7-22
U3D513E0.book Page 23 Monday, May 19, 2008 3:19 PM
7
7-23
U3D513E0.book Page 24 Monday, May 19, 2008 3:19 PM
7
CROSSING A SLOPE
Traversing a sloping surface on your ATV requires
you to properly position your weight to maintain
proper balance. Be sure that you have learned the
basic riding skills on flat ground before attempting
to cross a sloping surface. Avoid slopes with slippery surfaces or rough terrain that may upset your
balance.
As you travel across a slope, lean your body in the
uphill direction. It may be necessary to correct the
steering when riding on loose surfaces by pointing
the front wheels slightly uphill. When riding on
slopes, be sure not to make sharp turns either up
or down hill.
If your ATV does begin to tip over, gradually steer
in the downhill direction if there are no obstacles in
your path. As you regain proper balance, gradually
steer again in the direction you wish to travel.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any
hill until you have mastered the turning technique as described in the Owner’s Manual
on level ground. Be very careful when turning on any hill. Avoid crossing the side of a
steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described in the Owner’s Manual.
Avoid hills with excessively slippery or loose
surfaces.
Shift your weight to the uphill side of the
ATV.
EWB01141
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause the
ATV to overturn.
7-24
U3D513E0.book Page 25 Monday, May 19, 2008 3:19 PM
7
7-25
U3D513E0.book Page 26 Monday, May 19, 2008 3:19 PM
CROSSING THROUGH SHALLOW WATER
The ATV can be used to cross slow moving, shallow water of up to a maximum of 35 cm (14 in) in
depth. Before entering the water, choose your path
carefully. Enter where there is no sharp drop off,
and avoid rocks or other obstacles which may be
slippery or upset the ATV. Drive slowly and carefully.
EWB01150
WARNING
7
POTENTIAL HAZARD
Operating this ATV through deep or fast
flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and
loss of control, which could lead to an accident.
HOW TO AVOID THE HAZARD
Never operate this ATV in fast flowing water
or in water deeper than that specified in your
Owner’s Manual.
Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them
several times to let friction dry out the linings.
Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that you
have regained proper braking ability.
7-26
U3D513E0.book Page 27 Monday, May 19, 2008 3:19 PM
1. Air filter case check hose
ECB00730
7
NOTICE
After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case, the V-belt
cooling duct check hose, the drive select lever
box check hose and the storage compartment
drain plugs. Also, remove the V-belt case drain
plug to drain any water that may have accumulated. Wash the ATV in fresh water if it has been
operated in salt water or muddy conditions.
1. V-belt cooling duct check hose (left front side of ATV)
7-27
U3D513E0.book Page 28 Monday, May 19, 2008 3:19 PM
1. Drive select lever box check hose
1. V-belt case drain plug
RIDING OVER ROUGH TERRAIN
Riding over rough terrain should be done with caution. Look out for obstacles which could cause
damage to the ATV or could lead to an upset or accident. Be sure to keep your feet firmly mounted on
the footboards at all times. Avoid jumping the ATV
as loss of control and damage to the ATV may result.
7
EWB01160
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
1. Storage compartment drain plug
7-28
U3D513E0.book Page 29 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
Could cause loss of control or a collision.
Could cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Never attempt to ride over large obstacles,
such as large rocks or fallen trees. When
you go over obstacles, always follow proper
procedures as described in the Owner’s
Manual.
If the rear wheels of your ATV start to slide sideways, control can usually be regained (if there is
room to do so) by steering in the direction of the
slide. Applying the brakes or accelerating is not
recommended until you have corrected the slide.
SLIDING AND SKIDDING
Care should be used when riding on loose or slippery surfaces since the ATV may slide. If unexpected and uncorrected, sliding could lead to an
accident.
To reduce the tendency for the front wheels to slide
in loose or slippery conditions, positioning your
weight over the front wheels will sometimes help.
7-29
7
U3D513E0.book Page 30 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
You may lose control of this ATV. You may
also regain traction unexpectedly, which
may cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Learn to safely control skidding or sliding by
practicing at low speeds and on level,
smooth terrain.
On extremely slippery surfaces, such as ice,
go slowly and be very cautious in order to
reduce the chance of skidding or sliding out
of control.
7
WHAT TO DO IF...
This section is designed to be a reference guide
only. Be sure to read each section on riding techniques completely.
With practice, over a period of time, skill at controlled sliding can be developed. The terrain
should be chosen carefully before attempting such
maneuvers, since both stability and control are reduced. Bear in mind that sliding maneuvers should
always be avoided on extremely slippery surfaces
such as ice, since all control may be lost.
WHAT TO DO...
● If your ATV doesn’t turn when you want it to:
Bring the ATV to a stop and practice the turning
maneuvers again. Be sure you are putting your
weight on the footboard to the outside of the
turn. Position your weight over the front wheels
for better control. (See page 7-16.)
EWB01170
WARNING
POTENTIAL HAZARD
Skidding or sliding improperly.
7-30
U3D513E0.book Page 31 Monday, May 19, 2008 3:19 PM
●
●
●
●
●
If your ATV begins to tip while turning:
Lean more into the turn to regain balance. If necessary, gradually let off the throttle and/or steer
to the outside of the turn. (See page 7-16.)
If your ATV starts to slide sideways:
Steer in the direction of the slide if you have the
room. Applying the brakes or accelerating is not
recommended until you have corrected the
slide. (See page 7-29.)
If your ATV can’t make it up a hill you are trying
to climb:
Turn the ATV around if you still have forward
speed. If not, stop, dismount on the uphill side of
the ATV and physically turn the ATV around. If
the ATV starts to slip backwards, DO NOT USE
THE REAR BRAKE – the ATV may tip over on
top of you. Dismount the ATV on the uphill side.
(See page 7-18.)
If your ATV is traversing a sloping surface:
Be sure to ride with your weight positioned towards the uphill side of the ATV to maintain
proper balance. If the ATV starts to tip, steer
down the hill (if there are no obstacles in your
way) to regain balance. If you discover that the
ATV is going to tip over, dismount on the uphill
side. (See page 7-24.)
If your ATV encounters shallow water:
Ride slowly and carefully through slow moving
water, watching for obstacles. Be sure to let water drain from the ATV and CHECK YOUR
BRAKES FOR PROPER OPERATION when
you come out of the water. Do not continue to
ride your ATV until you have regained adequate
braking ability. (See page 7-26.)
EWB00010
WARNING
Indicates a potential hazard that could result in
serious injury or death.
7
7-31
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EBU21648
PERIODIC MAINTENANCE AND MINOR REPAIR
HOW TO AVOID THE HAZARD
Turn off the engine when performing maintenance unless otherwise specified. Have a
Yamaha dealer perform the service if you are
not familiar with maintenance work.
EBU21660
8
Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your
ATV in the safest and best operating condition
possible. The most important points of inspection,
adjustment, and lubrication are explained on the
following pages.
The intervals given in the periodic maintenance
and lubrication chart should be considered as a
general guide under normal riding conditions.
However, DEPENDING ON THE WEATHER,
TERRAIN, GEOGRAPHICAL LOCATION, AND
INDIVIDUAL USE, THE MAINTENANCE INTERVALS MAY NEED TO BE SHORTENED.
EBU21720
Owner’s manual and tool kit
Be sure to put this owner’s manual in the plastic
bag and always carry it on the bottom of the seat
as shown. Put the owner’s tool kit and low-pressure tire gauge under the seat.
EWB01820
WARNING
POTENTIAL HAZARD
Servicing an engine while it is running.
WHAT CAN HAPPEN
Moving parts can catch clothing or parts of
the body, causing injury.
Electrical components can cause shocks or
start fires.
8-1
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
EWB01830
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this ATV may cause changes in
handling which in some situations could
lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of accessories. All parts
and accessories added to this ATV should
be genuine Yamaha or equivalent components designed for use on this ATV and
should be installed and used according to
instructions. If you have questions, consult
an authorized Yamaha ATV dealer.
1. Owner’s manual
2. Owner’s tool kit
3. Low-pressure tire gauge
The service information included in this manual
and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. However,
additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
TIP
If you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
8-2
8
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
EBU21742
Periodic maintenance chart for the emission control system
TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
● For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
●
INITIAL
NO.
ITEM
8
1
*
2
Fuel line
Spark plug
3
*
Valves
4
*
Carburetor
5
*
Crankcase breather
system
CHECK OR MAINTENANCE
JOB
Whichever comes
first
month
1
3
km
(mi)
320
(200)
1300
(800)
hours
20
80
• Check fuel hoses for cracks or other damage, and
replace if necessary.
• Check condition and clean, regap, or replace if
necessary.
• Check valve clearance and adjust if necessary.
• Check starter (choke) operation and correct if necessary.
• Check engine idling speed and adjust if necessary.
• Check breather hose for cracks or other damage,
and replace if necessary.
8-3
√
√
√
√
EVERY
6
6
12
2500
2500
5000
(1600) (1600) (3200)
160
160
320
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
U3D513E0.book Page 4 Monday, May 19, 2008 3:19 PM
INITIAL
NO.
6
7
*
ITEM
Exhaust system
Spark arrester
CHECK OR MAINTENANCE
JOB
Whichever comes
first
month
1
3
km
(mi)
320
(200)
1300
(800)
hours
20
80
• Check for leakage and replace gasket(s) if necessary.
• Check for looseness and tighten all screw clamps
and joints if necessary.
• Clean.
EVERY
6
6
12
2500
2500
5000
(1600) (1600) (3200)
160
160
320
√
√
√
√
√
√
8
8-4
U3D513E0.book Page 5 Monday, May 19, 2008 3:19 PM
EBU21864
General maintenance and lubrication chart
INITIAL
NO.
ITEM
CHECK OR MAINTENANCE
JOB
Whichever comes
first
month
1
3
km
(mi)
320
(200)
1300
(800)
20
80
hours
1
2
3
Air filter element
*
*
Front brake
Rear brake
8
4
*
Brake hoses
5
*
Wheels
6
*
Tires
7
*
Wheel hub bearings
8
*
Swingarm
• Clean and replace if necessary.
• Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and
correct if necessary.
• Replace brake pads.
• Check operation and correct if necessary.
• Check brake lever and pedal free play, and adjust
if necessary.
• Replace brake shoes.
• Check for cracks or other damage, and replace if
necessary.
• Replace.
• Check runout and for damage, and replace if necessary.
• Check tread depth and for damage, and replace if
necessary.
• Check air pressure and balance, and correct if
necessary.
• Check for looseness or damage, and replace if
necessary.
• Check for excessive play, and correct if necessary.
8-5
EVERY
6
6
12
2500
2500
5000
(1600) (1600) (3200)
160
160
320
Every 20–40 hours (more often in wet or
dusty areas)
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
√
Whenever worn to the limit
√
√
√
√
Every 4 years
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
U3D513E0.book Page 6 Monday, May 19, 2008 3:19 PM
INITIAL
NO.
ITEM
9
*
V-belt
10
*
Chassis fasteners
11
*
12
*
Shock absorber assemblies
Steering shaft
13
*
Steering system
14
*
Engine mount
15
*
Axle boots
16
Engine oil
17
18
*
19
20
Engine oil filter cartridge
Engine oil strainer
Final gear oil
*
Moving parts and
cables
month
1
3
km
(mi)
320
(200)
1300
(800)
hours
20
80
• Check for wear, cracks or other damage, and replace if necessary.
• Make sure that all nuts, bolts, and screws are
properly tightened.
• Check operation and correct if necessary.
• Check for oil leakage and replace if necessary.
• Lubricate with lithium-soap-based grease.
• Check operation and repair or replace if damaged.
• Check toe-in and adjust if necessary.
• Check for cracks or other damage, and replace if
necessary.
• Check for cracks or other damage, and replace if
necessary.
• Change.
• Check ATV for oil leakage, and correct if necessary.
√
CHECK OR MAINTENANCE
JOB
Whichever comes
first
EVERY
6
6
12
2500
2500
5000
(1600) (1600) (3200)
160
160
320
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
• Replace.
√
√
√
• Clean.
• Change.
• Check ATV for oil leakage, and correct if necessary.
√
√
√
√
√
√
√
√
√
√
√
√
• Lubricate.
8-6
√
√
√
8
U3D513E0.book Page 7 Monday, May 19, 2008 3:19 PM
INITIAL
NO.
8
ITEM
21
*
Drive select lever
safety system cable
22
*
Throttle lever housing and cable
23
*
Front and rear brake
switches
24
*
Lights and switches
CHECK OR MAINTENANCE
JOB
Whichever comes
first
month
1
3
km
(mi)
320
(200)
1300
(800)
hours
20
80
• Check operation and adjust or replace if necessary.
• Check operation and correct if necessary.
• Check throttle cable free play and adjust if necessary.
• Lubricate throttle lever housing and cable.
EVERY
6
6
12
2500
2500
5000
(1600) (1600) (3200)
160
160
320
√
√
√
√
√
√
√
√
• Check operation and correct if necessary.
√
√
√
√
√
• Check operation and correct if necessary.
• Adjust headlight beams.
√
√
√
√
√
EBU28390
TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and calipers, and change
the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
●
8-7
U3D513E0.book Page 8 Monday, May 19, 2008 3:19 PM
EWB00010
EBU23111
Panel A
WARNING
Indicates a potential hazard that could result in
serious injury or death.
To remove the panel
Remove the bolt, and then take the panel off.
EBU23080
Removing and installing the panel
The panel shown needs to be removed to perform
some of the maintenance jobs described in this
chapter. Refer to this section each time the panel
needs to be removed and installed.
1. Panel A
2. Bolt
To install the panel
Place the panel in the original position and install
the bolt.
ECB00380
1. Panel A
NOTICE
When installing the panel, be sure not to pinch
the cables or wires.
8-8
8
U3D513E0.book Page 9 Monday, May 19, 2008 3:19 PM
2. Remove the spark plug as shown, with the
spark plug wrench included in the owner’s tool
kit.
EBU23211
Checking the spark plug
The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark
plug can reveal the condition of the engine.
To remove the spark plug
1. Remove the spark plug cap.
1. Spark plug wrench
8
To check the spark plug
1. Check that the porcelain insulator around the
center electrode of the spark plug is a medium-to-light tan (the ideal color when the ATV
is ridden normally).
TIP
If the spark plug shows a distinctly different color,
the engine could be operating improperly. Do not
attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the ATV.
1. Spark plug cap
8-9
U3D513E0.book Page 10 Monday, May 19, 2008 3:19 PM
2. Check the spark plug for electrode erosion
and excessive carbon or other deposits, and
replace it if necessary.
Specified spark plug:
NGK/DR8EA
To install the spark plug
1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap
to specification.
1. Spark plug gap
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
2. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.
Tightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
8-10
8
U3D513E0.book Page 11 Monday, May 19, 2008 3:19 PM
3. Remove the engine oil filler cap, and then
wipe the dipstick off with a clean rag.
TIP
If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
4. Install the spark plug cap.
EBU23315
Engine oil and oil filter cartridge
8
The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication
chart.
1. Engine oil filler cap
4. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.
To check the engine oil level
1. Place the ATV on a level surface.
2. Check the engine oil level on a cold engine.
TIP
If the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil settles for an accurate reading.
8-11
U3D513E0.book Page 12 Monday, May 19, 2008 3:19 PM
To change the engine oil (with or without oil filter cartridge replacement)
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place an oil pan under the engine to collect
the used oil.
3. Remove the engine oil filler cap, and then remove the engine oil drain bolt to drain the oil
from the crankcase.
1. Dipstick
2. Maximum level mark
3. Minimum level mark
TIP
The engine oil should be between the minimum
and maximum level marks.
8
5. If the engine oil is at or below the minimum
level mark, add sufficient oil of the recommended type to raise it to the correct level.
6. Insert the dipstick into the oil filler hole, and
then tighten the engine oil filler cap.
1. Engine oil drain bolt
TIP
Skip steps 4–6 if the oil filter cartridge is not being
replaced.
8-12
U3D513E0.book Page 13 Monday, May 19, 2008 3:19 PM
4. Remove the oil filter cartridge with an oil filter
wrench.
TIP
An oil filter wrench is available at a nearby Yamaha
dealer.
5. Apply a thin coat of engine oil to the O-ring of
the new oil filter cartridge.
TIP
Make sure that the O-ring is properly seated.
1. Oil filter cartridge
8
1. O-ring
6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified
torque with a torque wrench.
1. Oil filter wrench
8-13
U3D513E0.book Page 14 Monday, May 19, 2008 3:19 PM
Recommended oil:
See page 10-1.
Oil quantity:
Without oil filter cartridge replacement:
2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement:
2.30 L (2.43 US qt, 2.02 Imp.qt)
TIP
Be sure to wipe off spilled oil on any parts after the
engine and exhaust system have cooled down.
1. Torque wrench
ECB00300
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
NOTICE
● In order to prevent clutch slippage (since the
engine oil also lubricates the clutch), do not
mix any chemical additives. Do not use oils
with a diesel specification of “CD” or oils of
a higher quality than specified. In addition,
do not use oils labeled “ENERGY CONSERVING II” or higher.
● Make sure that no foreign material enters the
crankcase.
7. Install the engine oil drain bolt, and then tighten it to the specified torque.
Tightening torque:
Engine oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
8. Refill with the specified amount of the recommended engine oil, and then install and tighten the engine oil filler cap.
8-14
8
U3D513E0.book Page 15 Monday, May 19, 2008 3:19 PM
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
1
To check the final gear oil level
1. Place the ATV on a level surface.
TIP
The final gear oil level must be checked on a cold
engine.
2
2. Remove the final gear oil filler bolt, and then
check the oil level in the final gear case.
1. “CD” specification
2. “ENERGY CONSERVING II”
8
TIP
The oil level should be at the brim of the filler hole.
9. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
10. Turn the engine off, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
EBU23383
Final gear oil
The final gear case must be checked for oil leakage before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad8-15
U3D513E0.book Page 16 Monday, May 19, 2008 3:19 PM
2. Remove the final gear case guard by removing the bolts.
1. Final gear oil
2. Final gear oil filler bolt
3. Correct oil level
1. Final gear case guard
2. Bolt
3. If the oil is below the brim of the filler hole, add
sufficient oil of the recommended type to raise
it to the correct level.
4. Install the oil filler bolt, and then tighten it to the
specified torque.
3. Place an oil pan under the final gear case to
collect the used oil.
4. Remove the final gear oil filler bolt and the final gear oil drain bolt to drain the oil from the
final gear case.
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
To change the final gear oil
1. Place the ATV on a level surface.
8-16
8
U3D513E0.book Page 17 Monday, May 19, 2008 3:19 PM
1. Final gear oil drain bolt
1. Final gear oil
2. Final gear oil filler bolt
3. Correct oil level
5. Install the drain bolt, and then tighten it to the
specified torque.
8
Recommended final gear oil:
See page 10-1.
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
ECB00420
NOTICE
Be sure no foreign material enters the final
gear case.
6. Refill with the recommended final gear oil to
the brim of the filler hole as shown.
7. Install the oil filler bolt, and then tighten it to the
specified torque.
8-17
U3D513E0.book Page 18 Monday, May 19, 2008 3:19 PM
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
TIP
There is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air filter case.
8. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
9. Install the final gear case guard by installing
the bolts and tightening them to the specified
torque.
Tightening torque:
Final gear case guard bolt:
16 Nm (1.6 m·kgf, 11 ft·lbf)
EBU23635
Cleaning the air filter element
8
The air filter element should be cleaned at the intervals specified in the periodic maintenance and
lubrication chart. Clean or, if necessary, replace
the air filter element more frequently if you are
riding in unusually wet or dusty areas.
1. Air filter case check hose
1. Place the ATV on a level surface.
2. Remove the seat. (See page 4-12.)
3. Remove the air filter case cover by unhooking
the air filter case cover holders.
8-18
U3D513E0.book Page 19 Monday, May 19, 2008 3:19 PM
1. Air filter case cover holder
2. Air filter case cover
1. Air filter element
5. Pull off the air filter element lock plate, and
then remove the sponge material from the air
filter element frame.
4. Pull the air filter element out of the air filter
case.
8
8-19
U3D513E0.book Page 20 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Use parts cleaning solvent to clean the
sponge material.
7. Squeeze the excess solvent out of the sponge
material and let it dry.
ECB00440
NOTICE
Do not twist the sponge material when squeezing it.
1. Air filter element frame
2. Sponge material
3. Air filter element lock plate
6. Wash the sponge material gently but thoroughly in solvent.
8
EWB01900
WARNING
POTENTIAL HAZARD
Using low-flash-point solvents or gasoline to
clean the sponge material.
WHAT CAN HAPPEN
Low-flash-point solvents or gasoline can
catch fire or explode.
8. Check the sponge material and replace it if
damaged.
9. Apply Yamaha foam air filter oil or other quality foam air filter oil to the sponge material.
8-20
U3D513E0.book Page 21 Monday, May 19, 2008 3:19 PM
●
TIP
The sponge material should be wet but not dripping.
10. Pull the sponge material over the air filter element frame, and then install the lock plate.
11. Insert the air filter element into the air filter
case, and then install the air filter case cover
by hooking the holders onto the air filter case.
12. Install the seat.
8
Never operate the engine with the air filter element removed. This will allow unfiltered air
to enter the engine, causing rapid engine
wear and possible engine damage. Additionally, operation without the air filter element
will affect carburetor jetting with subsequent
poor performance and possible engine overheating.
EBU26451
Cleaning the spark arrester
TIP
The air filter element should be cleaned every 20–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty areas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fittings securely to avoid the possibility of unfiltered
air entering the engine.
Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
1. Remove the tailpipe cover by removing the
bolts.
2. Remove the tailpipe by pulling it out of the
muffler.
ECB00460
NOTICE
● Make sure that the air filter element is properly seated in the air filter case.
8-21
U3D513E0.book Page 22 Monday, May 19, 2008 3:19 PM
1. Bolt
2. Tailpipe cover
1. Tailpipe
2. Spark arrester
4. Insert the tailpipe into the muffler and align the
bolt holes.
5. Install the tailpipe cover by installing the bolts,
and then tighten them to the specified torque.
3. Tap the tailpipe lightly, and then use a wire
brush to remove any carbon deposits from the
spark arrester portion of the tailpipe and inside
of the tailpipe housing.
Tightening torque:
Tailpipe bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
8-22
8
U3D513E0.book Page 23 Monday, May 19, 2008 3:19 PM
EWB01910
WARNING
8
POTENTIAL HAZARD
Improper cleaning of the spark arrester.
Hot exhaust system.
WHAT CAN HAPPEN
Could injure the eyes.
Could cause burns.
Could cause carbon monoxide poisoning,
possibly leading to death.
Could start a fire.
HOW TO AVOID THE HAZARD
When cleaning the spark arrester:
Always let the exhaust system cool prior to
touching exhaust components.
Do not start the engine when cleaning the
exhaust system.
1. V-belt cooling duct check hose (left front side of ATV)
EBU23930
V-belt case drain plug
After riding in water deep enough to allow it to enter the V-belt case, remove this plug to drain the
water from the case.
TIP
If water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV as
the water may affect other engine parts.
EBU23920
V-belt cooling duct check hose
If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.
8-23
U3D513E0.book Page 24 Monday, May 19, 2008 3:19 PM
ECB00480
NOTICE
The carburetor has been set and extensively
tested at the Yamaha factory. Changing these
settings without sufficient technical knowledge may result in poor performance of or
damage to the engine.
EBU24000
Adjusting the engine idling speed
The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrication chart.
1. V-belt case drain plug
EBU23940
Adjusting the carburetor
The carburetor should be checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart. The
carburetor is an important part of the engine and
requires very sophisticated adjustment. Therefore,
most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment
described in the following section, however, may
be performed by the owner as part of routine maintenance.
TIP
A diagnostic tachometer is needed to make this
adjustment.
1. Start the engine and warm it up.
TIP
The engine is warm when it quickly responds to the
throttle.
2. Attach the tachometer to the spark plug lead.
3. Check the engine idling speed and, if necessary, adjust it to specification by turning the
throttle stop screw at the carburetor. To in8-24
8
U3D513E0.book Page 25 Monday, May 19, 2008 3:19 PM
crease the engine idling speed, turn the throttle stop screw in direction (a), and to decrease
it, turn the screw in direction (b).
EBU24045
Adjusting the throttle cable free play
The throttle cable free play should be checked
and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication
chart.
The throttle cable free play should measure 3.0–
5.0 mm (0.12–0.20 in) at the throttle lever. Periodically check the throttle cable free play and, if necessary, adjust it as follows.
TIP
The engine idling speed must be checked, and adjusted if necessary, before adjusting the throttle cable free play.
1. Throttle stop screw
8
1. Slide the rubber cover back.
2. Loosen the locknut.
3. To increase the throttle cable free play, turn
the throttle cable free play adjusting bolt in direction (a). To decrease the throttle cable free
play, turn the adjusting bolt in direction (b).
Engine idling speed:
1450–1550 r/min
TIP
If the specified idling speed cannot be obtained as
described above, have a Yamaha dealer make the
adjustment.
8-25
U3D513E0.book Page 26 Monday, May 19, 2008 3:19 PM
EBU24071
1
Adjusting the drive select lever safety
system cable
2
The drive select lever safety system cable stretches with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance and
lubrication chart.
3
4
1.
2.
3.
4.
EBU24120
Checking the front brake pads and rear
brake shoes
Rubber cover
Locknut
Throttle cable free play adjusting bolt
Throttle cable free play
The front brake pads and the rear brake shoes
must be checked for wear at the intervals specified
in the periodic maintenance and lubrication chart.
4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24171
Front brake pads
Check each front brake pad for damage and measure the lining thickness. If a brake pad is damaged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
EBU24060
Valve clearance
The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
8-26
8
U3D513E0.book Page 27 Monday, May 19, 2008 3:19 PM
1. Lining thickness
8
1. Wear limit line
2. Wear indicator
TIP
The wheels need to be removed to check the
brake pads. (See page 8-43.)
EBU24251
Checking the brake fluid level
Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become ineffective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if necessary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
EBU24180
Rear brake shoes
The rear brake is provided with a wear indicator,
which allows you to check the brake shoe wear
without having to disassemble the brake. To check
the brake shoe wear, check the position of the
wear indicator while applying the brake. If a brake
shoe has worn to the point that the wear indicator
reaches the wear limit line or mark, have a
Yamaha dealer replace the brake shoes as a set.
8-27
U3D513E0.book Page 28 Monday, May 19, 2008 3:19 PM
●
1
●
●
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will significantly lower the boiling point of the fluid and may
result in vapor lock.
Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid immediately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.
1. Minimum level mark
EBU24281
Changing the brake fluid
Observe these precautions:
● When checking the fluid level, make sure that
the top of the brake fluid reservoir is level.
● Use only the recommended quality brake fluid,
otherwise the rubber seals may deteriorate,
causing leakage and poor braking performance.
Have a Yamaha dealer change the brake fluid at
the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the brake master cylinder and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are damaged or leaking.
● Oil seals: Replace every two years.
● Brake hoses: Replace every four years.
Recommended brake fluid:
DOT 4
●
Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
8-28
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U3D513E0.book Page 29 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD
After servicing:
● Make sure the brakes operate smoothly
and that there is no free play.
● Make sure the brakes do not drag.
● Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
EBU24382
Checking the front brake lever free play
The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system.
EBU24503
Adjusting the brake pedal and rear
brake lever free play and checking the
brake pedal position
8
1. Brake lever free play
The brake pedal and brake lever free play must be
checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
EWB02460
WARNING
POTENTIAL HAZARD
Operating with improperly serviced or adjusted brakes.
TIP
Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.
●
8-29
U3D513E0.book Page 30 Monday, May 19, 2008 3:19 PM
●
Before adjusting the brake lever and brake pedal
free play, check the rear brake shoes for wear.
Adjusting the brake pedal free play
The brake pedal free play should measure 20.0–
30.0 mm (0.79–1.18 in) as shown. If the free play
is incorrect, adjust it as follows.
1. Brake pedal free play adjusting nut
2. Brake lever free play adjusting nut
Adjusting the brake lever free play
The brake lever free play should measure 3.0–5.0
mm (0.12–0.20 in) as shown. If the free play is incorrect, adjust it as follows.
1. Brake pedal free play
1. Fully loosen the brake lever free play adjusting nut on the brake cable at the rear wheel
hub.
2. Turn the brake pedal free play adjusting nut
on the brake cable at the rear wheel hub in direction (a) to increase the free play, and in direction (b) to decrease it.
8-30
8
U3D513E0.book Page 31 Monday, May 19, 2008 3:19 PM
1. Brake lever free play
2. Locknut
3. Brake lever free play adjusting bolt
8
1. Brake lever free play adjusting nut
2. Gap “A”
3. Turn the brake lever free play adjusting bolt at
the brake lever in direction (a) to increase the
free play, and in direction (b) to decrease it.
1. Loosen the locknut at the brake lever and fully
turn in the brake lever free play adjusting bolt.
2. Turn the brake lever free play adjusting nut on
the brake cable at the rear wheel hub so that
gap “A” measures 0–1 mm (0–0.04 in).
8-31
U3D513E0.book Page 32 Monday, May 19, 2008 3:19 PM
1
1. Distance between brake pedal and footboard bracket
1. Locknut
2. Brake lever free play adjusting bolt
4. Tighten the locknut at the brake lever.
TIP
When adjusting the rear brake lever free play:
● Be sure not to step on the brake pedal.
● Make sure the brake pedal does not move.
8
Checking the brake pedal position
The top of the brake pedal should be positioned
72.0–82.0 mm (2.83–3.23 in) above the footboard
bracket. If the brake pedal position is incorrect,
have a Yamaha dealer adjust it.
8-32
U3D513E0.book Page 33 Monday, May 19, 2008 3:19 PM
EWB02020
EBU24752
Brake light switches
WARNING
8
The operation of the brake light switches must be
checked and, if necessary, adjusted at the intervals specified in the periodic maintenance and lubrication chart.
The brake light switch for the brake pedal can be
adjusted as follows, but the other brake light
switches should be adjusted by a Yamaha dealer.
1. Remove panel A. (See page 8-8.)
POTENTIAL HAZARD
Operating with improperly serviced or adjusted brakes.
WHAT CAN HAPPEN
You could lose braking ability, which could
lead to an accident.
HOW TO AVOID THE HAZARD
After servicing:
● Make sure the brakes operate smoothly
and that the free play is correct.
● Make sure the brakes do not drag.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
TIP
The brake light switch is properly adjusted when
the brake light comes on just before braking takes
effect.
2. Turn the brake light switch adjusting nut while
holding the brake light switch in place. To
make the brake light come on earlier, turn the
adjusting nut in direction (a). To make the
brake light come on later, turn the adjusting
nut in direction (b).
EBU24230
Axle boots
The axle boots must be checked for damage at the
intervals specified in the periodic maintenance and
lubrication chart. Check the axle boots for tears or
damage. If any damage is found, have them replaced by a Yamaha dealer.
8-33
U3D513E0.book Page 34 Monday, May 19, 2008 3:19 PM
EWB02120
WARNING
POTENTIAL HAZARD
Damaged control cables.
WHAT CAN HAPPEN
Corrosion can result when the cable sheaths
become damaged, and cables can also become frayed or kinked, which could restrict
the operation of controls and lead to an accident or injury.
HOW TO AVOID THE HAZARD
Inspect cables frequently. Replace damaged
cables.
1. Brake light switch
2. Brake light switch adjusting nut
3. Install the panel.
EBU28711
Checking and lubricating the front and
rear brake levers
EBU24890
Checking and lubricating the cables
The operation and the condition of all control cables should be checked before each ride, and the
cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
Recommended lubricants:
Front brake lever:
Silicone grease
Rear brake lever:
Lithium-soap-based grease
Recommended lubricant:
Engine oil
8-34
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U3D513E0.book Page 35 Monday, May 19, 2008 3:19 PM
8
EBU28832
EBU24962
Checking and lubricating the brake
pedal
Checking the wheel hub bearings
The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is play
in a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bearings.
The operation of the brake pedal should be
checked before each ride, and the pedal pivot
should be lubricated if necessary.
TIP
To access the brake pedal pivot, remove panel A.
(See page 8-8.)
EBU25102
Lubricating the steering shaft
The steering shaft must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
Recommended lubricant:
Lithium-soap-based grease
8-35
U3D513E0.book Page 36 Monday, May 19, 2008 3:19 PM
HOW TO AVOID THE HAZARD
Avoid contact with skin, eyes or clothing. Always shield eyes when working near batteries. Keep out of reach of children.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Get prompt medical attention.
EYES: Flush with water for 15 minutes and
get prompt medical attention. Keep batteries
away from sparks, flames, cigarettes or other sources of ignition. Ventilate when charging or using in a closed space.
Recommended lubricant:
Lithium-soap-based grease
EBU29171
Battery
This model is equipped with a VRLA (Valve Regulated Lead Acid) battery. There is no need to check
the electrolyte or to add distilled water. However,
the battery lead connections need to be checked
and, if necessary, tightened.
ECB00620
NOTICE
Never attempt to remove the battery cell seals,
as this would permanently damage the battery.
EWB02140
WARNING
To remove the battery
1. Remove the seat. (See page 4-12.)
2. Remove the battery holding plate by removing
the bolts.
3. Disconnect the negative battery lead first,
then the positive battery lead by removing
their bolt.
POTENTIAL HAZARD
Failure to handle batteries or battery electrolyte carefully.
WHAT CAN HAPPEN
You could be poisoned. You could be severely burned by the sulfuric acid in battery
electrolyte. Batteries produce explosive gases.
8-36
8
U3D513E0.book Page 37 Monday, May 19, 2008 3:19 PM
ECB00930
NOTICE
To charge a VRLA (Valve Regulated Lead Acid)
battery, a special (constant-voltage) battery
charger is required. Using a conventional battery charger will damage the battery. If you do
not have access to a constant-voltage battery
charger, have a Yamaha dealer charge your
battery.
2
1
3
4
1.
2.
3.
4.
8
To store the battery
● If the ATV will not be used for more than one
month, remove the battery, fully charge it, and
then place it in a cool, dry place.
● If the battery will be stored for more than two
months, check it at least once a month and fully
charge it if necessary.
Battery holding plate
Bolt
Negative battery lead (black)
Positive battery lead (red)
4. Pull the battery out of its compartment.
To charge the battery
Have a Yamaha dealer charge the battery as soon
as possible if it seems to have discharged. Keep in
mind that the battery tends to discharge more
quickly if the ATV is equipped with optional electrical accessories.
To install the battery
TIP
Be sure the battery is fully charged.
1. Place the battery in its compartment.
2. Connect the positive battery lead first, then
the negative battery lead by installing their
bolt.
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U3D513E0.book Page 38 Monday, May 19, 2008 3:19 PM
EBU25313
Replacing a fuse
1. Positive battery lead (red)
2. Negative battery lead (black)
1. Main fuse
2. Spare main fuse
3. Fuse box
3. Install the battery holding plate by installing
the bolts.
4. Install the seat. (See page 4-12.)
ECB00940
NOTICE
Always keep the battery charged. Storing a discharged battery can cause permanent battery
damage.
8-38
8
U3D513E0.book Page 39 Monday, May 19, 2008 3:19 PM
2. Remove the blown fuse, and then install a
new fuse of the specified amperage.
1.
2.
3.
4.
8
Specified fuses:
Main fuse:
20.0 A
Headlight fuse:
15.0 A
Ignition fuse:
15.0 A
Signaling system fuse:
10.0 A
Headlight fuse
Ignition fuse
Signaling system fuse
Spare fuse
EWB02151
WARNING
POTENTIAL HAZARD
Using an improper fuse.
WHAT CAN HAPPEN
An improper fuse can cause damage to the
electrical system, which could lead to a fire.
HOW TO AVOID THE HAZARD
Always use a fuse of the specified rating.
Never use a material in place of the proper
fuse.
The main fuse and the fuse box are located under
the seat. (See page 4-12.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off all electrical
circuits.
ECB00640
NOTICE
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
8-39
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4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.
EBU25531
Replacing a headlight bulb
If a headlight bulb burns out, replace it as follows.
1. Remove the headlight bulb holder cover at the
rear of the headlight by pulling it off.
1. Headlight bulb holder
3. Remove the defective bulb from the headlight
unit by pulling it out.
EWB02180
WARNING
POTENTIAL HAZARD
A headlight bulb is hot when it is on and immediately after it is turned off.
WHAT CAN HAPPEN
You can be burned, or a fire could start if the
bulb touches something flammable.
HOW TO AVOID THE HAZARD
Wait for the bulb to cool before touching or
removing it.
1. Headlight bulb holder cover
2. Remove the headlight bulb holder by pushing
it inward and turning it counterclockwise.
8-40
8
U3D513E0.book Page 41 Monday, May 19, 2008 3:19 PM
5. Install the headlight bulb holder by aligning the
projections with the holes in the headlight unit,
pushing it inward, and turning it clockwise until
it stops.
4. Install a new headlight bulb into the headlight
unit by aligning the projection on the bulb with
the groove in the headlight unit.
1. Do not touch the glass part of the bulb.
8
6. Install the headlight bulb holder cover at the
rear of the headlight.
ECB00650
NOTICE
Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of the
bulb, and the bulb life will be adversely affected. Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth
moistened with alcohol or thinner.
ECB00670
NOTICE
Make sure the headlight bulb holder cover is
securely fitted over the bulb holder and seated
properly.
7. Adjust the headlight beam if necessary.
8-41
U3D513E0.book Page 42 Monday, May 19, 2008 3:19 PM
1. Remove the lens by removing the screws.
EBU25560
Adjusting a headlight beam
ECB00690
NOTICE
It is advisable to have a Yamaha dealer make
this adjustment.
To raise a headlight beam, turn the adjusting bolt
in direction (a).
To lower a headlight beam, turn the adjusting bolt
in direction (b).
1. Screw
2. Remove the defective bulb by pushing it in
and turning it counterclockwise.
1. Headlight beam adjusting bolt
EBU25600
Replacing the tail/brake light bulb
If the tail/brake light bulb burns out, replace it as
follows.
8-42
8
U3D513E0.book Page 43 Monday, May 19, 2008 3:19 PM
1. Tail/brake light bulb
8
1. Wheel nut
3. Elevate the ATV and place a suitable stand
under the frame.
4. Remove the nuts from the wheel.
5. Remove the wheel.
3. Insert a new bulb into the socket, push it in,
and then turn it clockwise until it stops.
4. Install the lens by installing the screws.
ECB00700
NOTICE
Do not overtighten the screws, otherwise the
lens may break.
EBU25701
Installing a wheel
1. Place the ATV on a level surface.
2. Install the wheel and the nuts.
EBU25651
Removing a wheel
TIP
The arrow mark
on the tire must point toward
the rotating direction of the wheel.
1. Place the ATV on a level surface.
2. Loosen the wheel nuts.
●
8-43
U3D513E0.book Page 44 Monday, May 19, 2008 3:19 PM
●
Tapered nuts are used for both the front and rear
wheels. Install the nuts with their tapered side towards the wheel.
1. Tapered nut
3. Lower the ATV to the ground.
4. Tighten the wheel nuts to the specified
torques.
1. Arrow mark
Tightening torques:
Front wheel nut:
55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear wheel nut:
55 Nm (5.5 m·kgf, 40 ft·lbf)
8-44
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HOW TO AVOID THE HAZARD
Do not smoke when checking the fuel system. Make sure there are no open flames or
sparks in the area, including pilot lights from
water heaters or furnaces.
EBU25710
Troubleshooting
8
Although Yamaha ATVs receive a thorough inspection before shipment from the factory, trouble
may occur during operation. Any problem in the fuel, compression, or ignition systems, for example,
can cause poor starting and loss of power.
The following troubleshooting chart represents a
quick and easy procedure for checking these vital
systems yourself. However, should your ATV require any repair, take it to a Yamaha dealer, whose
skilled technicians have the necessary tools, experience, and know-how to service the ATV properly.
Use only genuine Yamaha replacement parts. Imitation parts may look like Yamaha parts, but they
are often inferior, have a shorter service life and
can lead to expensive repair bills.
EWB02260
WARNING
POTENTIAL HAZARD
Checking the fuel system while smoking or
near an open flame.
WHAT CAN HAPPEN
Fuel can ignite or explode, causing severe
injury or property damage.
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U3D513E0.book Page 46 Monday, May 19, 2008 3:19 PM
EBU25751
Troubleshooting chart
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the ATV.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compression.
2. Compression
Operate the electric starter.
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gap, or replace the spark plug.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the ATV.
The engine does not start.
Check the battery.
Remove the spark plug
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
The engine turns over
slowly.
Check the battery lead connections,
and charge the battery if necessary.
Operate the electric starter.
8-46
The engine does not start.
Have a Yamaha dealer
check the ATV.
8
U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM
EBU25860
CLEANING AND STORAGE
ed from improper high-pressure detergent
applications such as those available in coinoperated car washers.
EBU25870
Cleaning
9
Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.
1. Before cleaning the ATV:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps
are properly installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply degreaser to the wheel axles.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bottle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean water and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
7. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protective finish. When finished cleaning, start the
engine and let it idle for several minutes.
ECB00710
NOTICE
Excessive water pressure may cause water
seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical devices. Many expensive repair bills have result-
EWB02300
WARNING
POTENTIAL HAZARD
Operation with wet brakes after washing.
9-1
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
WHAT CAN HAPPEN
Wet brakes may have reduced stopping ability, increasing the chance of an accident.
HOW TO AVOID THE HAZARD
Test the brakes after washing. Apply the
brakes several times at slow speeds to let
friction dry out the linings.
Long-term
Before storing your ATV for several months:
1. Follow all the instructions in the “Cleaning”
section of this chapter.
2. Turn the fuel cock lever to “OFF”.
3. Drain the carburetor float chamber by loosening the drain bolt; this will prevent fuel deposits
from building up. Pour the drained fuel into the
fuel tank.
4. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel from deteriorating.
EBU25932
Storage
Short-term
Always store your ATV in a cool, dry place and, if
necessary, protect it against dust with a porous
cover.
Specified amount:
7.5 ml of stabilizer to each liter of fuel (or 1 oz
of stabilizer to each gallon of fuel)
ECB00720
NOTICE
● Storing the ATV in a poorly ventilated room
or covering it with a tarp while it is still wet,
will allow water and humidity to seep in and
cause rust.
● To prevent corrosion, avoid damp cellars,
stables (because of the presence of ammonia) and areas where strong chemicals are
stored.
5. Perform the following steps to protect the cylinder, piston rings, etc. from corrosion.
a. Remove the spark plug cap and spark
plug.
b. Pour a teaspoonful of engine oil into the
spark plug bore.
9-2
9
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
6.
7.
9
8.
9.
°F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page
8-36.
c. Install the spark plug cap onto the spark
plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during
the next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.)
e. Remove the spark plug cap from the spark
plug, and then install the spark plug and
the spark plug cap.
Lubricate all control cables and the pivoting
points of all levers and pedals.
Check and, if necessary, correct the tire air
pressure, and then block up the ATV so that
all of its wheels are off the ground. Alternatively, turn the wheels a little every month in order
to prevent the tires from becoming degraded
in one spot.
Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
Remove the battery and fully charge it. Store
it in a cool, dry place and charge it once a
month. Do not store the battery in an excessively cold or warm place [less than 0 °C (30
TIP
Make any necessary repairs before storing the
ATV.
9-3
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EBU25960
SPECIFICATIONS
Dimensions:
Compression ratio:
9.20 :1
Starting system:
Electric starter
Lubrication system:
Wet sump
Overall length:
1978 mm (77.9 in)
Overall width:
1063 mm (41.9 in)
Overall height:
1095 mm (43.1 in)
Seat height:
840 mm (33.1 in)
Wheelbase:
1233 mm (48.5 in)
Ground clearance:
220 mm (8.7 in)
Minimum turning radius:
3000 mm (118 in)
Engine oil:
Type:
YAMALUBE 4 5W-30 or 10W-40 or 20W-50, SAE 5W-30
or SAE 10W-40 or SAE 20W-50
0
10
30
50
70
90
110
130 ˚F
Weight:
YAMALUBE 4 20W-50 or SAE 20W-50
With oil and fuel:
229.0 kg (505 lb)
YAMALUBE 4 10W-40 or SAE 10W-40
Engine:
Engine type:
Air cooled 4-stroke, SOHC
Cylinder arrangement:
Forward-inclined single cylinder
Displacement:
348.0 cm³
Bore × stroke:
83.0 × 64.5 mm (3.27 × 2.54 in)
10
YAMALUBE 4 5W-30 or SAE 5W-30
-20
-10
0
10
20
30
40
Recommended engine oil grade:
API service SG type or higher, JASO standard MA
10-1
50 ˚C
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
Clutch:
Engine oil quantity:
Without oil filter cartridge replacement:
2.20 L (2.33 US qt, 1.94 Imp.qt)
With oil filter cartridge replacement:
2.30 L (2.43 US qt, 2.02 Imp.qt)
Clutch type:
Wet, centrifugal automatic
Transmission:
Primary reduction system:
V-belt
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
41/21 × 24/18 × 33/9 (9.545)
Transmission type:
V-belt automatic
Operation:
Left hand operation
Forward gear:
35/20 (1.750)
Reverse gear:
26/15 (1.733)
Final gear oil:
Type:
SAE 80 API GL-4 Hypoid gear oil
Quantity:
0.23 L (0.24 US qt, 0.20 Imp.qt)
Air filter:
Air filter element:
Wet element
Fuel:
Recommended fuel:
Unleaded gasoline only
Fuel tank capacity:
14.5 L (3.83 US gal, 3.19 Imp.gal)
Fuel reserve amount:
4.5 L (1.19 US gal, 0.99 Imp.gal)
Chassis:
Frame type:
Steel tube frame
Caster angle:
4.0 °
Trail:
19.3 mm (0.76 in)
Carburetor:
10
Manufacturer:
MIKUNI
Type × quantity:
BSR33 x 1
Front tire:
Spark plug (s):
Type:
Tubeless
Size:
AT23 x 8-12
Manufacturer/model:
NGK/DR8EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)
10-2
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
Rear wheel:
Manufacturer/model:
MAXXIS/M937
Wheel type:
Panel wheel
Rim size:
12 x 7.5AT
Rear tire:
Type:
Tubeless
Size:
AT23 x 10-12
Manufacturer/model:
MAXXIS/M938
Front brake:
Type:
Dual disc brake
Operation:
Right hand operation
Recommended fluid:
DOT 4
Loading:
Maximum loading limit:
100.0 kg (220 lb)
(Total weight of rider, cargo, accessories, and tongue)
Rear brake:
Tire air pressure (measured on cold tires):
Type:
Drum brake
Operation:
Left hand and right foot operation
Recommended:
Front:
25.0 kPa (0.250 kgf/cm², 3.6 psi)
Rear:
25.0 kPa (0.250 kgf/cm², 3.6 psi)
Minimum:
Front:
22.0 kPa (0.220 kgf/cm², 3.2 psi)
Rear:
22.0 kPa (0.220 kgf/cm², 3.2 psi)
Front suspension:
Type:
Double wishbone
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
160 mm (6.3 in)
Front wheel:
Rear suspension:
Wheel type:
Panel wheel
Rim size:
12 x 6.0AT
Type:
Swingarm (monocross)
Spring/shock absorber type:
Coil spring/oil damper
Wheel travel:
180 mm (7.1 in)
10-3
10
U3D513E0.book Page 4 Monday, May 19, 2008 3:19 PM
Electrical system:
Ignition fuse:
15.0 A
Ignition system:
DC. CDI
Charging system:
AC magneto
Battery:
Model:
YTX14AH
Voltage, capacity:
12 V, 12.0 Ah
Headlight:
Bulb type:
Krypton bulb
Bulb voltage, wattage × quantity:
10
Headlight:
12 V, 30.0/30.0 W × 2
Tail/brake light:
12 V, 5.0/21.0 W × 1
Neutral indicator light:
12 V, 1.7 W × 1
Reverse indicator light:
12 V, 1.7 W × 1
Oil temperature warning light:
12 V, 1.7 W × 1
Fuses:
Main fuse:
20.0 A
Headlight fuse:
15.0 A
Signaling system fuse:
10.0 A
10-4
U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM
EBU25981
CONSUMER INFORMATION
EBU26011
EBU26020
Identification numbers
Key identification number
The key identification number is stamped into the
key. Record this number in the space provided and
use it for reference when ordering a new key.
Record the key identification number, vehicle identification number and model label information in
the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the ATV is stolen.
KEY IDENTIFICATION NUMBER:
VEHICLE IDENTIFICATION NUMBER:
1. Key identification number
MODEL LABEL INFORMATION:
EBU26030
Vehicle identification number
The vehicle identification number is stamped into
the frame.
11-1
11
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
1. Vehicle identification number
1. Model label
TIP
The vehicle identification number is used to identify
your ATV.
EBU26050
11
Model label
The model label is affixed at the location in the illustration. Record the information on this label in
the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
11-2
U3D513E0.book Page 3 Monday, May 19, 2008 3:19 PM
EBU26060
Noise regulation
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by
any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
These acts include tampering with the following systems; i.e., modification, removal, etc.
Exhaust system
• Muffler
• Exhaust pipe
• Silencer
Intake system
• Air cleaner case
• Air cleaner element
• Intake duct
11
11-3
U3D513E0.book Page 4 Monday, May 19, 2008 3:19 PM
EBU26080
Maintenance record
Copies of work orders and/or receipts for parts you purchase and install will be required to document maintenance done in accordance with the warranty. The chart below is printed only as a reminder to you that the
maintenance work is required. It is not acceptable proof of maintenance work.
MAINTENANCE INTERVAL
month
km (mi)
hours
1
3
6
12
18
24
30
36
42
48
54
60
320 (200)
1300 (800)
2500 (1600)
5000 (3200)
7500 (4800)
10000 (6400)
12500 (8000)
15000 (9600)
17500 (11200)
20000 (12800)
22500 (14400)
25000 (16000)
20
80
160
320
480
640
800
960
1120
1280
1440
1600
DATE OF
SERVICE
MILEAGE
11
11-4
SERVICING DEALER
NAME AND ADDRESS
REMARKS
U3D513E0.book Page 5 Monday, May 19, 2008 3:19 PM
EBU26501
YAMAHA MOTOR CORPORATION, U.S.A. ATV LIMITED WARRANTY
Yamaha Motor Corporation, U.S.A. hereby warrants
that new Yamaha ATVs purchased from an
authorized Yamaha ATV dealer in the continental
United States will be free from defects in material and
workmanship for the period of time stated herein, subject to certain stated limitations.
THE PERIOD OF WARRANTY for Yamaha ATVs
shall be six (6) months from the date of purchase.
DURING THE PERIOD OF WARRANTY any authorized
Yamaha ATV dealer will, free of charge, repair or
replace any part adjudged defective by Yamaha due
to faulty workmanship or material from the factory.
Parts used in warranty repairs will be warranted for
the balance of the product’s warranty period. All parts
replaced under warranty become property of Yamaha
Motor Corp. U.S.A.
GENERAL EXCLUSIONS from this warranty shall
include any failures caused by:
a. Competition or racing use.
b. Installation of parts or accessories that are not
qualitatively equivalent to genuine Yamaha parts.
c. Abnormal strain, neglect, or abuse.
d. Lack of proper maintenance.
e. Accident or collision damage.
f. Modification to original parts.
g. Damage due to improper transportation.
SPECIFIC EXCLUSIONS from this warranty shall
include parts replaced due to normal wear or routine
maintenance, such as spark plugs, oil, oil filter, air filter,
and brake shoes.
THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:
1. Operate and maintain the ATV as specified in the
appropriate owner’s manual;
2. Give notice to an authorized Yamaha ATV dealer
of any and all apparent defects within ten (10) days
after discovery, and make the machine available at
that time for inspection and repairs at such dealer’s
place of business.
WARRANTY TRANSFER: To transfer the warranty
from the original purchaser to any subsequent purchaser(s), it is imperative that the machine be
inspected and registered for warranty by an authorized Yamaha ATV dealer. In order for this warranty
to remain in effect, this inspection and registration
must take place within ten (10) days after transfer. An
inspection and registration fee will be charged for this
service.
EMISSION CONTROL SYSTEM WARRANTY
Yamaha Motor Corporation, USA also warrants to
the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha
ATV covered by this warranty that the vehicle is
designed, built, and equipped so as to conform at the
time of sale with all U.S. emissions standards
applicable at the time of manufacture and that it is
free from defects in materials and workmanship
which would cause it not to meet these standards
within the period listed immediately below. Failures
other than those resulting from defects in material or
workmanship which arise solely as a result of owner
abuse and/or lack of proper maintenance are not
covered by this warranty.
All Models
Thirty (30) months from the original purchase date
YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO
OTHER WARRANTY OF ANY KIND, EXPRESSED OR
IMPLIED. ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE WHICH EXCEED THE
OBLIGATIONS AND TIME LIMITS STATED
IN THIS WARRANTY ARE HEREBY DISCLAIMED
BY YAMAHA MOTOR CORPORATION, U.S.A. AND
EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO THE
ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO
EXCLUDED FROM THIS WARRANTY ARE ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES
INCLUDING LOSS OF USE. SOME STATES DO NOT
ALLOW THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS
WHICH VARY FROM STATE TO STATE.
YAMAHA MOTOR CORPORATION, U.S.A.
P.O. Box 6555
Cypress, California 90630
11
11-5
U3D513E0.book Page 6 Monday, May 19, 2008 3:19 PM
WARRANTY QUESTIONS AND ANSWERS
CUSTOMER SERVICE
Q. What costs are my responsibility during the warranty period?
A. The customer’s responsibility includes all costs of normal maintenance services,
non-warranty repairs, accident and collision damages, and oil, oil filters, air filters,
spark plugs, and brake shoes.
If your machine requires warranty service, you must take it to any authorized
Yamaha ATV dealer within the continental United States. Be sure to bring
your warranty registration card or other valid proof of the original date of
purchase. If a question or problem arises regarding warranty, first contact
the owner of the dealership. Since all warranty matters are handled at the
dealer level, this person is in the best position to help you. If you are still
not satisfied and require additional assistance, please write:
Q. What are some examples of “abnormal” strain, neglect, or abuse?
A. These terms are general and overlap each other in areas. Specific examples include:
Running the machine out of oil, sustained high rpm, full-throttle, operating the
machine with a broken or damaged part which causes another part to fail, damage
or failure due to improper or careless transportation and or tie-down. If you have
any specific questions on operation or maintenance, please contact your dealer
for advice.
YAMAHA MOTOR CORPORATION U.S.A.
CUSTOMER RELATIONS DEPARTMENT
P.O. Box 6555
Cypress, California 90630
When contacting Yamaha Motor Corporation, U.S.A. don’t forget to include
any important information such as names, addresses, model, V.I.N. (frame
number), dates, and receipts.
Q. Does the warranty cover incidental costs such as towing or transportation due to
a failure?
A. No. The warranty is limited to repair of the machine itself.
CHANGE OF ADDRESS
Q. May I perform any or all of the recommended maintenance shown in the Owner’s
Manual instead of having the dealer do them?
A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s
and Service Manual. We do recommend, however, that items requiring
special tools or equipment be done by a Yamaha ATV dealer.
The federal government requires each manufacturer of a motor vehicle to
maintain a complete, up-to-date list of all first purchasers against the
possibility of a safety-related defect and recall. This list is compiled from
the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the
selling dealer at the time of your purchase.
Q. Will the warranty be void or cancelled if I do not operate or maintain my new ATV
exactly as specified in the Owner’s Manual?
A. No. The warranty on a new ATV cannot be “voided” or “cancelled.” However,
if a particular failure is caused by operation or maintenance other than as described
in the Owner’s Manual, that failure may not be covered under warranty.
11
If you should move after you have purchased your new ATV, please advise
us of your new address by sending a postcard listing your ATV model
name, V.I.N. (frame number), dealer number (or dealer’s name) as it is
shown on your warranty card, your name and new mailing address. Mail to:
Q. What responsibility does my dealer have under this warranty?
A. Each Yamaha ATV dealer is expected to:
1. Completely set up every new machine before sale.
2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.
3. Each Yamaha ATV dealer is held responsible for his setup, service and warranty repair work.
YAMAHA MOTOR CORPORATION, U.S.A.
P.O. Box 6555
Cypress, California 90630
Attention: Warranty Department
This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date
registration record in accordance with federal law.
Q. Is the warranty transferable to second owners?
A. Yes. The remainder of the existing warranty can be transferred upon request. The
unit has to be inspected and re-registered by an authorized Yamaha ATV dealer
for the policy to remain effective.
11-6
U3D513E0.book Page 7 Monday, May 19, 2008 3:19 PM
EBU26122
YAMAHA EXTENDED SERVICE (Y.E.S.)
Keep your Yamaha protected even after your warranty
expires with genuine Yamaha Extended Ser vice (Y.E.S.).
In addition, Travel and Recreation Interruption Protection
(TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
expenses you incur because your Yamaha needs
covered service: replacement vehicle rental, emergency
towing, phone calls, even food and lodging when you are
away from home. This superb coverage goes into effect
when you purchase Y.E.S., so it applies to any warranty
repairs as well as covered repairs during your entire
Y.E.S. plan period.
Y.E.S. is designed and administered by Yamaha Motor
Corporation to provide maximum owner satisfaction. You
get uninterrupted factor y-backed coverage for extra
peace of mind.
Y. E. S. is flexible. You choose the plan that’s right for
you: 12 months, 24 months, or 36 months beyond your
warranty period.
Y.E.S. coverage is honored at any authorized Yamaha
dealer nationwide.
Y.E.S. is designed and administered by the same
Yamaha people who handle your warranty – and it
shows in the comprehensive coverage benefits. There
are no mileage limitations. Coverage isn’t limited to
“moving par ts” or the “drive train” like many other plans.
And Y.E.S. covers manufacturing defects just like the
warranty. See the sample contract at your Yamaha
dealer to see how comfor ting uninterr upted factor ybacked protection can be.
Y.E.S. coverage is transferable to a new owner if you
sell or trade in your ATV. That can make your Yamaha
much more valuable!
This excellent Y.E.S. plan coverage is only available to
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
you how easy it is to protect your investment with Yamaha
Extended Service.
You don’t have to pay anything for covered repairs.
T h e r e ’s n o d e d u c t i b l e t o p ay, a n d r e p a i r s a r e n ’ t
“pro-rated.” You don’t have any “out-of-pocket” expenses
for covered repairs.
11
11-7
U3D513E0.book Page 8 Monday, May 19, 2008 3:19 PM
We urge you to act now. You’ll get the excellent benefits of
TRIP coverage right away, and you’ll rest easy knowing
you’ll have strong factory-backed protection even after your
Yamaha Limited Warranty expires. You can also save
money: Y.E.S. costs less within the first 90 days after you
buy your Yamaha. See your dealer today!
A special note:
If visiting your dealer isn’t convenient, contact Yamaha with
your Primar y ID number (your frame number). We’ll be
happy to help you get the Y.E.S. coverage you need.
Yamaha Service Marketing
P.O. Box 6555
Cypress, CA 90630
11
WARNING
Indicates a potential hazard that could
result in serious injury or death.
11-8
U3D513E0.book Page 9 Monday, May 19, 2008 3:19 PM
EBU26132
11
11-9
U3D513E0.book Page 1 Monday, May 19, 2008 3:19 PM
INDEX
A
E
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-18
Axle boots .................................................................... 8-33
Engine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-24
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-11
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-3
B
Battery .......................................................................... 8-36
Brake fluid, changing .................................................... 8-28
Brake fluid level, checking ............................................ 8-27
Brake lever free play, checking the front ...................... 8-29
Brake lever, front ............................................................ 4-5
Brake levers, checking and lubricating ......................... 8-34
Brake light switches ..................................................... 8-33
Brake pads and shoes, checking ................................. 8-26
Brake pedal and brake lever free play (rear) and
brake pedal position, adjusting and checking ............ 8-29
Brake pedal and rear brake lever ................................... 4-6
Brake pedal, checking and lubricating ......................... 8-35
Brakes, front and rear .................................................... 5-4
C
Cables, checking and lubricating ................................. 8-34
Carburetor, adjusting .................................................... 8-24
Chassis fasteners ........................................................... 5-8
Cleaning ......................................................................... 9-1
F
Final gear oil .......................................................... 5-3, 8-15
Fuel ......................................................................... 4-8, 5-3
Fuel cock ...................................................................... 4-10
Fuel tank cap .................................................................. 4-8
Fuses, replacing ........................................................... 8-38
H
Handlebar switches ........................................................ 4-3
Headlight beam, adjusting ............................................ 8-42
Headlight bulb, replacing .............................................. 8-40
I
Identification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-8
K
D
Drive select lever ............................................................ 4-7
Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ......... 8-26
Key identification number ............................................. 11-1
L
Label locations ............................................................... 2-1
Light switch .................................................................... 4-3
U3D513E0.book Page 2 Monday, May 19, 2008 3:19 PM
M
Main switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Maintenance record ..................................................... 11-4
Model label ................................................................... 11-2
N
Neutral indicator light ..................................................... 4-2
Noise regulation ........................................................... 11-3
O
Oil temperature warning light ......................................... 4-2
Owner’s manual and tool kit ........................................... 8-1
P
Panel, removing and installing ....................................... 8-8
Parking ........................................................................... 6-6
Parking brake ................................................................. 4-7
Parking on a slope ......................................................... 6-6
Part locations ................................................................. 3-1
Pre-operation check list ................................................. 5-1
R
Reverse indicator light ................................................... 4-2
Riding your ATV ............................................................. 7-1
S
Safety information .......................................................... 1-1
Seat .............................................................................. 4-12
Shock absorber assemblies, adjusting the front .......... 4-14
Shock absorber assembly, adjusting the rear .............. 4-15
Spark arrester, cleaning ............................................... 8-21
Spark plug, checking ...................................................... 8-9
Specifications ............................................................... 10-1
Speed limiter .................................................................. 4-4
Starter (choke) ............................................................. 4-11
Start switch .................................................................... 4-3
Steering shaft, lubricating ............................................ 8-35
Storage .......................................................................... 9-2
Storage compartment .................................................. 4-13
T
Tail/brake light bulb, replacing ..................................... 8-42
Throttle cable free play, adjusting ................................ 8-25
Throttle lever ........................................................... 4-4, 5-5
Tire pressure, measuring ............................................... 5-7
Tires ............................................................................... 5-6
Tire wear limit ................................................................ 5-8
Troubleshooting ........................................................... 8-45
Troubleshooting chart .................................................. 8-46
V
Valve clearance ........................................................... 8-26
V-belt case drain plug .................................................. 8-23
V-belt cooling duct check hose .................................... 8-23
Vehicle identification number ....................................... 11-1
W
Warranty, extended ..................................................... 11-7
Warranty, limited .......................................................... 11-5
Wheel hub bearings, checking ..................................... 8-35
Wheel, installing ........................................................... 8-43
Wheel, removing .......................................................... 8-43
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B6-yoko.fm Page 1 Wednesday, March 8, 2006 10:46 AM
EBU26151
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH.
BEER
BEER
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
ALWAYS:
without proper training or instruction.
use proper riding techniques to avoid
at speeds too fast for your skills or the
vehicle overturns on hills and rough
conditions.
terrain and in turns.
on public roads-a collision can occur with
avoid paved surfaces-pavement may
another vehicle.
seriously affect handling and control.
with a passenger-passengers affect
balance and steering and increase risk
of losing control.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
(For replacement manual, call 1-800-532-1558)
YAMAHA MOTOR CO., LTD.
PRINTED IN USA
2008.05-0.4×1 CR
(E)
DIC183